CN115570088A - Automatic roll forging forming production line - Google Patents

Abstract

The automatic roll forging forming production line is provided with a plurality of induction heating furnaces connected in series through transmission rollers, and a clamping roller is arranged at the feeding end of each induction heating furnace; a feeding roller is arranged concentrically with the clamping roller; a material storage rack is arranged perpendicular to the feeding roller; the discharge end at the tail end of the induction heating furnace is concentrically connected with a discharge roller and a positioning oil cylinder; a receiving roller is arranged on one side parallel to the discharging roller at an interval, and a hydraulic roll forging machine with a forging station and a forging manipulator are arranged on the other side; a longitudinal crossing type feeding and discharging rotating mechanism of the truss manipulator is arranged on the longitudinal vertical crossing forging station, the discharging roller and the material receiving roller so as to drive the workpiece to longitudinally displace, vertically lift and rotate for 360 degrees; a stepping slow cooling chain plate roller way and a blanking roller are concentrically arranged at the discharge end of the receiving roller; the vertical linking blanking roller is provided with a stacking device. The automatic continuous production line adopts low-cost structural improvement, realizes automatic continuous production of products such as the point rail from feeding, heating and forging, particularly turning, overturning and discharging, and has the advantages of simple structure, economy, practicability and high production efficiency.

Description

Automatic roll forging forming production line

Technical Field

The invention belongs to the technical field of operation and transportation metal forging machinery, and particularly relates to an automatic roll forging forming production line.

Background

In the switch markets of state railways, subways and heavy haul railways, the demand of alloy steel frog products is on the trend of rising year by year, at least one forged alloy steel center rail is needed in alloy steel frog products with different structural types and rail types, and two forged alloy steel wing rail insert blocks are needed in part of products.

At present, because of the special forging structure of the alloy steel frog product, the blank is manufactured by adopting the traditional free forging process, and the problems of large machining allowance and low material utilization rate exist; the total amount of products is considerable, but the economy of developing die forgings is not achieved at the present stage due to the fact that the types of the products are numerous. The roller forging production process adopted at present solves the problem that the free forging process is insufficient, and simultaneously well avoids the problems of large tonnage of equipment required by die forging production, multiple die types and low economic benefit caused by small single product batch; therefore, the roll forging production process is the best forging process method for producing alloy steel frog center and wing rail forgings at the present stage.

In the prior art, some manufacturers have developed research and application of related technologies of roll forging production, but the equipment automation degree and the production efficiency are not high, the process is laggard, and an automatic continuous production line from feeding, heating, forging, turning, overturning to discharging is not formed.

Taking an automatic roll forging production system of the chinese patent with publication number CN210387417U as an example, although the automatic continuous production of feeding, heating and roll forging is realized, the production system is only suitable for the continuous roll forging production of some small parts on one hand, and especially cannot realize the turning roll forging processing of blanks on the other hand; thus resulting in inefficient processing and unsuitability for processing long products.

On the contrary, aiming at the insert structure of long products such as a center rail and a wing rail, on the basis of the existing roll forging production technology, the advanced induction heating, automatic material taking, program forging and automatic blanking collection equal-item mature technology in the roll forging industry is applied; through integrated design, an automatic roll forging forming production line is developed, and the automatic roll forging forming production line is used for realizing full-flow automatic continuous production from feeding, heating, forging to turning, overturning and discharging of long-size products such as center rail and wing rail insert block structures, and achieves the economical and continuous production targets of full-automatic roll forging production.

Disclosure of Invention

The technical problems solved by the invention are as follows: the utility model provides an automatic roll forging shaping production line, adopt vertical leap discharge station, forge the station, connect the material station the vertical leap formula truss manipulator unloading rotary mechanism who connects, combine the 360 rotatory functions of unloading rotary mechanism on vertical leap formula truss manipulator, and the feed roll, continuous through induction heating stove, the discharge roll, hydraulic pressure roll forging machine, the forging manipulator, connect the material roller, marching type slowly-cooling link joint roll table, the unloading roller, the pile up neatly device, the effective integration of unloading frame, how to adopt low-cost institutional advancement and the modularization combination between the equipment, realize the automatic continuous production problem of product from material loading, heating, forging, turn around, upset, to unloading such as heart rail, wing rail insert.

The technical scheme adopted by the invention is as follows: an automatic roll forging forming production line comprises a hydraulic roll forging machine and an induction heating furnace; the hydraulic roll forging machine and the induction heating furnace are transversely arranged in parallel at intervals; the induction heating furnaces are provided with a plurality of induction heating furnaces, and adjacent induction heating furnaces are transversely concentrically connected in series through the transmission rollers to form a continuous through type induction heating furnace group; the feeding end part of the induction heating furnace is provided with a clamping roller; a feeding roller is concentrically and collinearly arranged with the clamping roller; a material storage rack is arranged perpendicular to the conveying direction of the feeding roller; the discharge end of the induction heating furnace at the tail end is concentrically connected with one end of a discharge roller; the other end of the discharging roller is concentrically provided with a positioning oil cylinder; the feeding roller is arranged on one side of the discharging roller, and the hydraulic roll forging machine and the forging manipulator which are concentric are arranged on the other side of the discharging roller; a forging station is arranged between the hydraulic roll forging machine and the forging manipulator, and the hydraulic roll forging machine and the forging manipulator are simultaneously a forging rotation working area; the longitudinal vertical crossing forging station, the discharge roller and the receiving roller are provided with a longitudinal crossing type feeding and discharging rotating mechanism of the truss manipulator; the feeding and discharging rotating mechanism of the longitudinal crossing type truss manipulator drives a workpiece to longitudinally displace, vertically lift and rotate by 360 degrees; a stepping slow cooling chain plate roller way is concentrically arranged at the discharge end of the receiving roller; the tail end of the stepping slow cooling chain plate roller way transmission is concentrically provided with a blanking roller; and a stacking device is vertically connected with the discharging roller.

In the above technical solution, further: the control method comprises a full-automatic control mode, a pure manual control mode and a step-by-step semi-automatic control mode.

In the above technical solution, further: the material storage racks are used for parallelly placing workpieces which are lifted in place one by one at intervals; the storage rack consists of a plurality of independent brackets which are vertically arranged at equal intervals; the upper supporting surface of the independent bracket, which is contacted with the workpiece, is provided with a transmission chain plate; the transmission chain plate is used for vertical material transmission.

In the above technical solution, further: the material storage rack is provided with a feeding button; when no material is detected on the feeding roller but the material is on the storage rack, the feeding button is pressed down, and the storage rack automatically and vertically conveys the workpiece on the storage rack to the central position of the feeding roller and then stops conveying; and when the induction heating furnace stops, the feeding roller starts to start after detecting that the workpiece is in place and transversely conveys the workpiece to a furnace mouth of the first induction heating furnace.

In the above technical solution, further: the clamping rollers and the transmission rollers have the same structure but different functions, the clamping rollers are used for clamping and biting workpieces, and the transmission rollers are used for continuously conveying the workpieces; the clamping roller is provided with two or more adjacent clamping rollers, and the conveying roller is provided with one clamping roller; when the front workpiece is completely separated from the clamping roller, the clamping roller detects that no material exists; the feeding roller starts to automatically feed the rear workpiece so as to realize the continuous feeding of the induction heating furnace; wherein the rotational speed and the clamping force of the clamping roller are always the same as the rotational speed and the clamping force of the transfer roller.

In the above technical solution, further: the clamping roller is provided with a displacement sensor; when the displacement sensor detects that the workpiece is transmitted to a positioning displacement value between the upper roller and the lower roller of the clamping roller, the roller body of the clamping roller is automatically ejected out to bite the workpiece, and the clamping roller clamps the workpiece according to a set rotating speed and moves in the induction heating furnace at a constant speed for feeding.

In the above technical solution, further: the discharging roller and the feeding roller are both active transmission roller ways; the discharging roller and the feeding roller have the same structure and are concentric and collinear; and after the workpiece reaches the fixed position of the discharging roller, triggering a working signal of a positioning oil cylinder, and ejecting the workpiece out of the furnace by the positioning oil cylinder according to a set numerical value to adjust the central position of the workpiece out of the furnace, so that the center of the workpiece out of the furnace is always positioned right below the clamping station of the feeding and discharging rotating mechanism of the longitudinal crossing type truss manipulator.

In the above technical solution, further: the step-by-step slow cooling chain plate roller way is an active chain plate transmission mechanism; the material receiving roller has the same structure as the roller way of the stepping slow cooling chain plate; the total length of a continuous roller way consisting of the stepping slow cooling chain plate roller way and the receiving roller is at least three times of the length of a formed workpiece; the outer side of the whole transmission direction of the stepping slow cooling chain plate roller way is matched with a heat shield.

In the above technical solution, further: the blanking roller is in a powerless blanking roller structure; the stacking device is provided with a stacking manipulator and a blanking frame; the stacking manipulator is used for clamping a workpiece which is formed on the blanking roller in place and vertically transferring the workpiece to the blanking frame; the blanking frames are parallelly arranged one by one at intervals and used for transferring the formed workpieces in place.

In the above technical solution, preferably: the forging manipulator has the functions of clamping, loosening, advancing, retreating and clamping and rotating.

In the above technical solution, preferably: the feeding and discharging rotating mechanism on the longitudinal crossing type truss manipulator is provided with a material grabbing manipulator which has the functions of linearly displacing along the horizontal direction, linearly lifting along the vertical direction and rotating 360 degrees in the horizontal plane.

Compared with the prior art, the invention has the advantages that:

1. based on the existing roll forging process, the automatic assembly line production from feeding, heating, forging and discharging of workpieces is realized; especially, the turning forging function of the workpiece is realized through the reasonable layout of the feeding and discharging rotating mechanism of the longitudinal crossing type truss manipulator capable of clamping the workpiece to rotate for 360 degrees, so that the investment of equipment is saved, the forging time is greatly shortened, the forging efficiency is improved, and the automatic continuous roll forging production line with the advanced process is provided.

2. The continuous through type induction heating furnace adopts the existing induction heating furnace to concentrically and serially connect the furnace body through the transmission roller, is combined with the clamping roller to bite the workpiece, does not need to design a new induction heating furnace, adopts the existing induction heating furnace to effectively and serially connect, realizes the continuous pre-forging heating of the workpiece with the long axial length, realizes the one-fire pre-forging heating of the workpiece with the long axial length such as a center rail, improves the heating efficiency before forging, reduces the heating cost before forging, and is suitable for popularization.

3. According to the invention, through an integrated design, the existing automatic material taking, automatic program forging and automatic blanking collection and other mature technologies are used, and the lifting, longitudinal moving and rotating functions of a feeding and discharging rotating mechanism of a longitudinal crossing type truss manipulator and the workpiece overturning function of a forging manipulator are combined to form an automatic roll forging forming production line, so that the full-flow automatic continuous production of products with the same length and size, such as a center rail insert block structure and a wing rail insert block structure, from feeding, heating, forging to turning, overturning and blanking is realized, and the economical and continuous production target of full-automatic roll forging production is achieved.

4. The forging manipulator has the functions of clamping, loosening, advancing, retreating and material clamping and rotating; the clamping and rotating function of the forging machine can realize the overturning forging of workpieces and meet the adaptive overturning forging requirements of railheads and railbottoms of workpieces with complex shapes.

5. The stepping slow cooling chain plate roller way meets the technical requirement of slow cooling of the alloy steel forge piece after forging, and the adaptive heat shield reduces a large amount of heat radiation of an operation field and improves the operation environment.

6. The technical scheme of matching the storage rack, the feeding roller, the clamping roller and the transmission roller realizes the continuous feeding of the induction heating furnace.

7. According to the technical scheme, the positioning oil cylinder is arranged at the end of the discharging roller, so that the accurate positioning of blanks with different lengths after being discharged from the furnace is realized, and the material grabbing manipulator can be clamped in the middle of the blank every time.

8. The hydraulic roll forging machine adopts the plane roll forging disclosed in the Chinese patent ZL202020742783.1, does not need to replace a roll forging die, and realizes roll forging forming production of workpieces with the maximum length of large long-axis forgings of different specifications of 4m and the single weight of 500 kg.

9. The automatic stacking device provided by the invention realizes automatic collection and stacking of the forged slow-cooling formed workpieces after blanking, saves manpower and realizes the establishment of an automatic continuous and complete roll forging production line.

Drawings

FIG. 1 is a schematic diagram of an integrated layout according to the present invention;

FIG. 2 is an enlarged detail view of the storage rack, the feed roller and the clamping roller in FIG. 1;

FIG. 3 is a first structural schematic diagram based on PLC control according to the present invention;

FIG. 4 is a structural schematic block diagram II based on PLC control according to the present invention;

FIG. 5 is a first flowchart of the present invention;

FIG. 6 is a second flow chart of the present invention;

FIG. 7 is a third flowchart of the present invention;

FIG. 8 is a first control circuit diagram for implementing the automatic control functions and processes of FIGS. 3-4 and 5-7 based on Siemens 1500PLC in accordance with the present invention;

FIG. 9 is a second control circuit diagram of the present invention based on Siemens 1500PLC to implement the automatic control functions and processes of FIGS. 3 to 4 and FIGS. 5 to 7;

FIG. 10 is a first ladder diagram of the process for implementing the automatic control process of FIGS. 3-4 and 5-7 based on Siemens 1500PLC according to the present invention;

FIG. 11 is a second program ladder diagram for implementing the automatic control process of FIGS. 3-4 and 5-7 based on Siemens 1500PLC in accordance with the present invention;

in the figure: 1-a storage rack, 101-an independent bracket and 102-a transmission chain plate; 2-feeding roller, 3-induction heating furnace, 3-1 clamping roller, 3-2 transmission roller, 4-discharging roller, 4-1 positioning oil cylinder, 5-longitudinal crossing type truss manipulator feeding and discharging rotating mechanism, 5-1 gantry, 5-2 grabbing manipulator, 6-forging manipulator, 7-hydraulic roll forging machine, 8-receiving roller, 9-stepping slow cooling chain plate roller way, 9-1 heat insulation cover, 10-stacking device, 10-1 discharging roller, 10-2 discharging frame and 11-forging piece rotating work area.

Detailed Description

The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to fig. 1 to 11 in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be obtained by a person skilled in the art without making any creative effort based on the embodiments in the present invention, belong to the protection scope of the present invention.

An automatic roll forging forming production line comprises a hydraulic roll forging machine 7 and an induction heating furnace 3.

The hydraulic roll forging machine 7 is a self-grinding plane roll hydraulic roll forging machine 7 disclosed in Chinese patent ZL202020742783.1, and has the advantages of simple and reasonable structural design, suitability for roll forging of long variable cross-section forgings, no limitation of the diameters of a roll and a die on the length of a workpiece, high production efficiency and low processing cost. The length of the forged piece is not limited by the size of a roller of the roll forging machine, and the height position of the upper roller is continuously adjustable in the roll forging process; the adjustment of the center distance of the upper and lower rollers adopts a piston cylinder driving mode, thereby not only realizing the accurate and large-amplitude adjustment of the center distance of the upper and lower rollers, but also providing enough pressing force in the roll forging process; when the upper roller and the lower roller synchronously rotate in opposite directions and the upper roller presses downwards, the control requirements of different cross section height sizes in the length direction of the workpiece can be met; the rotary power of the upper and lower rollers is provided by the upper and lower hydraulic motors respectively, and the volume is smaller compared with the conventional motor driving mode. The upper roller and the lower roller adopt a plane roller structure form, the workpiece is bitten in the middle, and the height sizes of different cross sections of the workpiece are realized by synchronously pressing the upper roller in the rotating process of the upper roller and the lower roller. The upper roller is fixedly arranged on the lower portion of the movable cross beam, the lower roller is fixedly arranged on the upper portion of the lower cross beam and is driven by hydraulic pressure, the upper roller is driven by a piston oil cylinder to realize adjustment of the upper position and the lower position, the hydraulic motor drives the upper roller and the lower roller to realize opposite rotation respectively, the upper roller and the lower roller are both of a planar structure, continuous extension and forming of long-shaft workpieces can be realized, the roll forging process adopts program control, and different section height dimension control of long-strip forged pieces can be realized by independent or simultaneous adjustment of the rotating speed of the rollers and the displacement of the upper roller.

The induction heating furnace 3 is a chinese patent with publication number CN114777475A and named as "a medium frequency induction heating furnace system for fork processing", and has a feeding mechanism, an induction heating furnace with a medium frequency IGBT power supply, a tool lifting mechanism and a discharging mechanism. When the medium-frequency induction heating furnace is adopted to carry out heat treatment on a workpiece, the time of the heat treatment process of the workpiece is shortened, the energy consumption is reduced, and the processing efficiency is improved; this intermediate frequency induction heating furnace adopts feed mechanism to carry out automatic feeding, discharge mechanism carries out automatic discharging, does not need artifical transport work piece, reduces workman intensity of labour. The material feeding and discharging device is combined and used in series, and has the advantages of continuous material feeding and discharging functions and uniform workpiece heating temperature.

The hydraulic roll forging machine 7 and the induction heating furnace 3 are transversely arranged in parallel at intervals (shown in figure 1); the induction heating furnaces 3 are provided with a plurality of induction heating furnaces, and adjacent induction heating furnaces 3 are transversely concentrically connected in series through transmission rollers 3-2 to form a continuous through type induction heating furnace group; the continuous through type induction heating furnace group is used for realizing the continuous pre-forging heating transmission function of the long axial workpiece.

The feeding end part of the induction heating furnace 3 is provided with a clamping roller 3-1; in the above embodiment, further: the clamping roller 3-1 and the transmission roller 3-2 are identical in structure and different in function, the clamping roller 3-1 is used for clamping and biting workpieces, and the transmission roller 3-2 is used for realizing continuous transmission of the workpieces. The conveying roller 3-2 has one, and the grip roller 3-1 has two or more closely adjacent rollers.

The specific structure of the clamping roller 3-1 and the conveying roller 3-2 is a Chinese patent with the name of clamping roller feeding device for induction diathermy furnace disclosed in the publication number of CN 208818001U. The clamping roller 3-1 and the transmission roller 3-2 which adopt the structural characteristics are combined with the induction heating furnace 3 with the tandem structure for use, and have the functions and effects of continuous feeding, improving the operation efficiency and reducing the cost.

In the above embodiment, further: the clamping roller 3-1 is provided with a displacement sensor; specifically, the displacement sensor is arranged at the position 15mm from the front end of the clamping roller 3-1. When the displacement sensor detects that the workpiece is transmitted to a positioning displacement value between an upper roller and a lower roller of the clamping roller 3-1, the roller body of the clamping roller 3-1 is automatically ejected out to bite the workpiece, and the clamping roller 3-1 clamps the workpiece according to a set rotating speed and moves and feeds the workpiece into the induction heating furnace 3 at a constant speed.

Specifically, the displacement sensor is arranged at the position 15mm at the front end of the clamping roller 3-1, when the displacement sensor detects that the workpiece is displaced to the distance of 15mm, the end part of the workpiece is proved to abut against the front end of the clamping roller 3-1, the clamping roller 3-1 is triggered to act, the roller body of the clamping roller is automatically ejected out to bite the workpiece, and the workpiece can be successfully bitten to be reliably clamped for conveying.

A feeding roller 2 is concentrically and collinearly arranged with the clamping roller 3-1; and a storage rack 1 is arranged perpendicular to the conveying direction of the feeding roller 2. In the above embodiment, further: the material storage frames 1 are used for parallelly placing workpieces which are lifted in place one by one at intervals; the storage rack 1 consists of a plurality of independent supports 101 which are vertically arranged at equal intervals; the upper supporting surface of the independent bracket 101, which is contacted with the workpiece, is provided with a transmission chain plate 102; the conveying chain plates 102 are used for vertical conveying. The transmission chain plate 102 is realized by a speed reducing motor, a driving chain wheel and driving chain wheel shaft driven by the speed reducing motor, a chain, a driven chain wheel and driven chain wheel shaft, and a transmission chain plate connected with the chain. To prevent the chain from collapsing, the independent support 101 is provided with several anti-collapse rollers.

In the above embodiment, further: the material storage rack 1 is provided with a feeding button; when the feeding roller 2 detects that no material exists but the material exists on the material storage rack 1, the material loading button is pressed down, and the material storage rack 1 automatically vertically conveys the workpiece on the material storage rack to the central position of the feeding roller 2 and then stops conveying.

To achieve the center stop function: and a photoelectric sensor is arranged at the central position of the feed roller 2. When photoelectric sensor detected that the work piece targets in place, photoelectric sensor sent the effective signal of telecommunication towards PLC, and PLC control storage frame 1 stops the transmission, and when storage frame 1 stopped the transmission, feeding roller 2 detected that the work piece targets in place and began to start, and after starting feeding roller 2 transversely carried the work piece to the fire door of first induction heating furnace 3.

An in-place detection sensor is installed near the furnace mouth of the induction heating furnace 3, and after the in-place detection sensor detects that the workpiece is in place, a clamping roller 3-1 described later is triggered to start to act.

On the basis of the embodiment, when the front workpiece is completely separated from the clamping roller 3-1 and enters the induction heating furnace 3 and the clamping roller 3-1 detects no material; the feeding roller 2 and the storage rack 1 start automatic feeding and back position work pieces so as to realize continuous feeding of the induction heating furnace 3.

The implementation of the continuous feed function described above also requires the use of sensors in combination. Specifically, a detection sensor arranged at the front end of the clamping roller 3-1 is used for detecting whether a material exists in the vicinity of the clamping roller, and once no material is detected, the workpiece is proved to completely enter the induction heating furnace 3, and the automatic feeding of the material storage rack 1 and the feeding roller 2 is triggered.

Wherein, for continuity and stability of guaranteeing the continuous pay-off transmission of heating before forging: the rotating speed and the clamping force of the clamping roller 3-1 are always the same as those of the transmission roller 3-2.

The discharge end of the induction heating furnace 3 at the tail end is concentrically connected with one end of a discharge roller 4; and a positioning oil cylinder 4-1 is concentrically arranged at the other end of the discharging roller 4.

In the above embodiment, further: the discharging roller 4 and the feeding roller 2 are both active transmission roller ways; the discharging roller 4 and the feeding roller 2 are same in structure, concentric and collinear. The specific structure of the feed roller 2 and the discharge roller 4 is disclosed in chinese patent with publication number CN215556320U and name "a roller way conveying device". The structure is selected, and the automatic transportation has the characteristic of no need of manual work; and the annular groove in the middle of the roller body can enable the workpiece to be transported in the middle, so that the workpiece is prevented from sliding out of the roller way.

And after the workpiece reaches the fixed position of the discharge roller 4, triggering a working signal of a positioning oil cylinder 4-1, and ejecting the positioning oil cylinder 4-1 according to a set numerical value to adjust the central position of the discharged workpiece, so that the center of the discharged workpiece is always positioned right below a clamping station of a feeding and discharging rotating mechanism 5 of the longitudinal crossing type truss manipulator described later, namely the position for clamping the workpiece is clamped in the middle position of the workpiece every time, and the clamping stability is ensured.

Specifically, a photoelectric sensor is installed at a fixed position of the discharging roller 4, when a workpiece reaches a photoelectric sensor installation position, an emitting end of the photoelectric sensor is shielded by the workpiece, and the photoelectric sensor sends an effective electric signal to a PLC to indicate that the workpiece is transmitted in place; at the moment, the PLC output end triggers a working signal towards the positioning oil cylinder 4-1, a piston rod of the positioning oil cylinder 4-1 is ejected out by a set length according to a set value so as to push the workpiece to retreat, and the center of the workpiece retreated according to the set value is just positioned right below the clamping station of the feeding and discharging rotating mechanism 5 of the longitudinal crossing type truss manipulator, so that the reliability of subsequent clamping of the workpiece is ensured.

The material receiving roller 8 is arranged on one side of the discharging roller 4 and is parallel to the discharging roller 4 at intervals, and the specific structure of the material receiving roller 8 refers to a Chinese patent with the name of 'a roller way conveying device' which is disclosed in the publication number CN 215556320U. The starting end of the receiving roller 8 is a receiving station, and the other side of the discharging roller 4 is provided with a hydraulic roll forging machine 7 and a forging manipulator 6 which are concentric.

And a forging station is arranged between the hydraulic roll forging machine 7 and the forging manipulator 6, and the hydraulic roll forging machine and the forging manipulator are simultaneously a forging rotation working area 11. The workpiece is in a forging station between the hydraulic roll forging machine 7 and the forging manipulator 6, so that the overturning forging function and the turning forging function of the workpiece are realized.

In the above embodiment, further: the forging manipulator 6 has the functions of clamping, loosening, advancing, retreating and clamping and rotating; the "forging manipulator" is a prior art, and is referred to a chinese patent with a name of "a forging manipulator" disclosed in publication No. CN205464137U, and is used for completing clamping, loosening, advancing, retreating, especially clamping and rotating actions of a workpiece.

For realizing the automatic circulation function of the workpiece from the heating station before forging to the forging station and the receiving and discharging station: and a longitudinal crossing type truss manipulator feeding and discharging rotating mechanism 5 is arranged on the longitudinal vertical crossing forging station, the discharging roller 4 and the receiving roller 8. The feeding and discharging rotating mechanism 5 of the longitudinal crossing type truss manipulator drives the workpiece to longitudinally displace, vertically lift and rotate for 360 degrees.

Particularly, the feeding and discharging rotating mechanism 5 of the longitudinal crossing type truss manipulator is used for realizing the logistics circulation of the workpiece at a forging station, a discharging station of the discharging roller 4 and a discharging station of the receiving roller 8.

Namely further: the feeding and discharging rotating mechanism of the longitudinal crossing type truss manipulator is provided with a material grabbing manipulator 5-2, and the material grabbing manipulator 5-2 has the functions of linear displacement along the horizontal direction, linear lifting along the vertical direction and 360-degree rotation in the horizontal plane.

It should be noted that: the material grabbing manipulator 5-2 realizes the functions of linear displacement along the horizontal direction and 360-degree rotation in the horizontal plane, and the disclosure number is as follows: CN208759113U, entitled as a "feeding and discharging mechanism for truss manipulator". And the linear lifting function of the material grabbing manipulator 5-2 along the vertical direction is realized by adding a linear lifting mechanism to the material grabbing manipulator 5-2.

Further, the execution end of the linear lifting mechanism carries on a horizontal displacement mechanism of a material grabbing manipulator, and the horizontal displacement mechanism of the material grabbing manipulator carries on a 360-degree rotating mechanism of the material grabbing manipulator.

On the basis of the above steps: a stepping slow cooling chain plate roller way 9 is concentrically arranged at the discharge end of the receiving roller 8; the stepping slow cooling chain plate roller way 9 is used for realizing the stepping transmission and stepping slow cooling functions of the forged workpiece.

In the above embodiment, further: the step-type slow cooling chain plate roller way 9 is an active chain plate transmission mechanism; namely comprises a frame, a chain transmission mechanism and a chain plate anti-falling supporting roller way. The chain transmission mechanism comprises a speed reducing motor, a driving chain wheel shaft, a driven chain wheel and a driven chain wheel shaft, wherein the speed reducing motor drives the driving chain wheel and the driving chain wheel shaft to rotate, and the driving chain wheel and the driven chain wheel are meshed with each other to bypass a chain so as to drive the chain to move; a horizontal chain plate is arranged on the displaced chain; the bottom of the horizontal chain plate is provided with a chain plate anti-falling supporting roller way which is a non-active roller way, and the supporting roller way is uniformly distributed along the rack at equal intervals to support the bottom of the chain plate so as to prevent the chain plate from falling and collapsing.

The receiving roller 8 and the stepping slow cooling chain plate roller way 9 are the same in structure to form a long slow cooling transmission structure. The total length of a continuous roller way formed by the stepping slow cooling chain plate roller way 9 and the material receiving roller 8 is at least three times of the length of a formed workpiece, so that the full slow cooling function is met. The stepping slow cooling chain plate roller way 9 meets the technical requirement of slow cooling of the alloy steel forge piece after forging.

Further, the method comprises the following steps: the outer side of the stepping slow cooling chain plate roller way 9 in the whole transmission direction is matched with a heat insulation cover 9-1. The heat shield 9-1 adapted to the transmission direction of the stepping slow cooling chain plate roller way 9 effectively reduces a large amount of heat radiation on an operation site and improves the operation environment.

The conveying tail end of the stepping slow cooling chain plate roller way 9 is concentrically provided with a blanking roller 10-1; and a stacking device 10 is vertically connected with the blanking roller 10-1. The specific structure of the blanking roller 10-1 is disclosed in Chinese patent with publication No. CN215556320U and named as a roller way conveying device.

In the above embodiment, further: the blanking roller 10-1 is of a powerless blanking roller structure; the stacking device 10 is provided with a stacking manipulator and a blanking frame 10-2; the stacking manipulator is used for clamping a workpiece which is formed in place on the blanking roller 10-1 and vertically transferring the workpiece to the blanking frame 10-2; the blanking frame 10-2 parallelly arranges the formed workpieces transferred in place by the stacking manipulator one by one at intervals.

The specific structure of the stacking device 10 refers to a chinese patent with publication number CN 114590603A, which is entitled "an automatic aluminum round bar stacking apparatus", and the stacking device has the stacking manipulator and the blanking frame, and the stacking manipulator has the function of placing formed workpieces at equal intervals.

On the basis, the automatic roll forging forming production line comprises a full-automatic control mode, a pure manual control mode and a step-by-step semi-automatic control mode based on a PLC (programmable logic controller) with a Siemens brand and a 1500 model.

The working process of the full-automatic control mode, especially the ladder diagram of the program written in the full-automatic mode operation, refers to the attached drawing of the specification.

The pure manual control mode and the distributed semi-automatic control mode are respectively carried out through the existing manual control keys and semi-automatic control programs of all the equipment without modification.

The working principle of the invention is as follows: manually hoisting the materials to the storage rack 1 one by one and placing the materials at intervals; the feeding button is pressed down, and the storage rack 1 automatically and vertically conveys a first workpiece to the center of the feeding roller 2 at a fixed distance; after the feeding roller 2 detects that the workpiece is in position at the center position, the feeding roller 2 is started, and the feeding roller 2 transversely conveys the first workpiece to a furnace mouth of the induction heating furnace 3; a sensor is arranged at a furnace mouth of the induction heating furnace 3, and is used for detecting whether a workpiece is in place or not and triggering the clamping roller 3-1 to act after detecting that the workpiece is in place; the clamping rollers 3-1 arranged at the furnace mouth of the first induction heating furnace 3 clamp materials up and down and bite the workpiece to start rotating, and the workpiece is clamped at constant speed by the two adjacent clamping rollers 3-1 and bited into the workpiece and is sent into the hearth of the induction heating furnace 3 at constant speed; when the clamping roller 3-1 is started, the conveying roller 3-2 is synchronously started; the multiple induction heating furnaces 3 are connected with the adjacent induction heating furnaces 3 through the transmission rollers 3-2 to form a continuous series hearth, so that the continuous pre-forging heating and continuous transmission of the long axial length workpiece are realized; when the first workpiece is completely separated from the clamping roller 3-1 and the clamping roller 3-1 detects no material, triggering the storage rack 1 and the feeding roller 2 to start the subsequent automatic material supplementing operation; namely, the second workpiece is automatically fed and the actions are repeated until all the workpieces on the storage rack 1 enter the furnace, thereby realizing the continuous automatic feeding of the induction heating furnace 3. Meanwhile, each workpiece is advanced at a constant speed and continuously heated in the hearth by the transmission rollers 3-2 arranged at intervals until the last workpiece is discharged onto the discharge roller 4 through the induction heating furnace 3 at the tail end; a detection sensor arranged on the discharging roller 4 detects whether a workpiece is in place, when the discharging roller 4 detects that the workpiece is in place, when the workpiece reaches the discharging roller 4, a working signal of a positioning oil cylinder 4-1 is triggered, the positioning oil cylinder 4-1 ejects a piston rod according to a set numerical value, and the ejected piston rod pushes the workpiece to move for adjusting the discharging position of the workpiece, so that the middle part of the workpiece after the workpiece moves is always right under the clamping station of the feeding and discharging rotating mechanism 5 of the longitudinal crossing type truss manipulator, and reliable clamping of the feeding and discharging rotating mechanism 5 of the longitudinal crossing type truss manipulator to the workpiece is ensured; the positioning oil cylinder 4-1 automatically retreats and resets after a piston rod pushes a fixed value, the positioning oil cylinder 4-1 automatically retreats and resets, and simultaneously, the feeding and discharging rotating mechanism 5 of the longitudinal crossing type truss manipulator is triggered to start operation, and the material grabbing manipulator 5-2 of the feeding and discharging rotating mechanism 5 of the longitudinal crossing type truss manipulator after the operation is started longitudinally moves to a position right above a workpiece of the discharging roller 4 from a starting zero position; the material grabbing manipulator 5-2 clamps materials after descending, the material grabbing manipulator 5-2 reliably clamps materials and then ascends for resetting, the material grabbing manipulator 5-2 ascends in place drives a workpiece to longitudinally displace to a forging station after the workpiece is lifted in place, the material grabbing manipulator 5-2 descends, the workpiece is loosened after the workpiece is descended in place, and the workpiece is received by the forging manipulator 6; after the forging manipulator 6 successfully receives the material, the material grabbing manipulator 5-2 ascends, and the ascended material grabbing manipulator 5-2 longitudinally displaces to the initial zero position to be processed; the forging manipulator 6 clamps materials and combines with the hydraulic roll forging machine 7 to roll forge and form one end of the workpiece in multiple passes; after the hydraulic roll forging machine 7 rolls and forges one end of the workpiece, the forging manipulator 6 loosens the workpiece and retreats; the material grabbing manipulator 5-2 longitudinally moves to the roll forging position again; the material grabbing manipulator 5-2 descends again and clamps the materials; the material grabbing manipulator 5-2 clamps the workpiece and discharges the material after rotating for 180 degrees to realize the turn-around rotation of the workpiece, and the material grabbing manipulator 5-2 loosens the turned-around workpiece; the forging manipulator 6 is used for re-receiving the other end of the workpiece, is combined with the hydraulic roll forging machine 7 to forge the other end of the turned workpiece for multiple times, and performs forging forming on the turned workpiece under the operation of a forging program of the turning end; after the workpiece is roll-forged and formed, the forging manipulator 6 loosens the workpiece again and retreats; the material grabbing manipulator 5-2 returns to the forging station to grab materials; the material grabbing manipulator 5-2 clamps the formed forged piece and moves to the material receiving station of the material receiving roller 8, then stops moving and descends to loosen the formed workpiece, and after the material receiving roller 8 detects that the workpiece is in place, the material receiving roller 8 starts to start and sends the formed workpiece into the stepping slow cooling chain plate roller way 9; the stepping slow cooling chain plate roller way 9 is used for slowly cooling and transmitting the formed workpiece to a blanking roller 10-1; after the feeding roller 10-1 detects that the workpiece is in place, the stacking device 10 is triggered to start to operate, the stacking device 10 transfers the formed workpiece with the feeding roller 10-1 in place to the feeding rack 10-2 to be stacked in order, and therefore continuous, efficient, economical, practical and reliable roll forging automatic continuous production of workpieces with long axial lengths such as center rails is completed. The ladder diagram of the program required to be modified for realizing the full-automatic function is shown in the attached drawings of the specification and is not described again.

From the above description it can be found that: the invention is based on the existing roll forging process, and realizes the automatic flow line production from feeding, heating, forging and discharging of workpieces; especially, the turning forging function of the workpiece is realized through the reasonable layout of the feeding and discharging rotating mechanism 5 of the longitudinal crossing type truss mechanical arm capable of clamping the workpiece to rotate for 360 degrees, so that the equipment investment is saved, the forging time is greatly shortened, the forging efficiency is improved, and the automatic continuous roll forging production line with the advanced process is provided.

According to the continuous pass type induction heating furnace 3, the existing induction heating furnace 3 is adopted to concentrically and serially connect the furnace body through the transmission roller 3-2, the clamping roller 3-1 is combined to bite the workpiece, a new induction heating furnace 3 is not required to be designed, the existing induction heating furnace 3 is effectively and serially connected, the continuous pre-forging heating of the workpiece with the long axial length is realized, the one-fire pre-forging heating of the workpiece with the long axial length such as a center rail is realized, the heating efficiency before forging is improved, the heating cost before forging is reduced, and the continuous pass type induction heating furnace is suitable for popularization.

According to the invention, through an integrated design, the existing automatic material taking, automatic program forging and automatic blanking collection and other mature technologies are used, and the lifting, longitudinal moving and rotating functions of a feeding and discharging rotating mechanism of a longitudinal crossing type truss manipulator and the workpiece overturning function of a forging manipulator 6 are combined to form an automatic roll forging forming production line, so that the full-flow automatic continuous production of products with the same size, such as a center rail insert block structure and a wing rail insert block structure, from feeding, heating, forging to turning, overturning and blanking is realized, and the economical and continuous production target of full-automatic roll forging production is achieved.

The forging manipulator has the functions of clamping, loosening, advancing, retreating and clamping and rotating; the clamping and rotating function of the forging machine can realize the overturning forging of workpieces and meet the adaptive overturning forging requirements of railheads and railbottoms of workpieces with complex shapes.

The stepping slow cooling chain plate roller way meets the technical requirement of slow cooling of the alloy steel forge piece after forging, and the adaptive heat shield 9-1 reduces a large amount of heat radiation on an operation site and improves the operation environment.

The technical scheme of the invention that the storage rack 1, the feeding roller 2, the clamping roller 3-1 and the transmission roller 3-2 are matched realizes the continuous feeding of the induction heating furnace 3.

According to the invention, by adopting the technical scheme that the positioning oil cylinder 4-1 is arranged at the end of the discharging roller 4, the accurate positioning of the blanks with different lengths after discharging is realized, and the clamping manipulator 5-2 can be ensured to be clamped in the middle of the blank each time.

The hydraulic roll forging machine 7 adopts the plane roll forging disclosed in the Chinese patent ZL202020742783.1, does not need to replace a roll forging die, and realizes roll forging forming production of workpieces with the maximum length of large long-axis forgings of different specifications of 4m and the single weight of 500 kg.

The automatic stacking device provided by the invention realizes automatic collection and stacking of the forged slow-cooling formed workpieces after blanking, saves labor and realizes the establishment of an automatic, continuous and complete roll forging production line.

In conclusion, the reasonable layout of the feeding and discharging rotating mechanism of the longitudinal crossing type truss manipulator which longitudinally crosses a discharging station, a forging station and a material receiving station is adopted, and the 360-degree rotating function of the feeding and discharging rotating mechanism of the longitudinal crossing type truss manipulator is combined, and the feeding roller, the continuous passing type induction heating furnace, the discharging roller, the hydraulic roll forging machine, the forging manipulator, the material receiving roller, the stepping slow cooling chain plate roller way, the discharging roller, the stacking device and the material receiving frame are effectively integrated; the automatic continuous production device effectively solves the problem of how to adopt low-cost structural improvement to realize automatic continuous production from feeding, heating, forging, turning, overturning to blanking of products such as the center rail and the wing rail insert. Particularly, the invention adopts the structural improvement with low cost to realize the automatic continuous production of products such as the point rail from feeding, heating, forging, particularly turning, overturning and discharging; the production line has the advantages of simple structure, economy, practicability, high production efficiency and suitability for popularization.

All the embodiments in the present specification are described in a related manner, and the same and similar parts among the embodiments may be referred to each other, and each embodiment focuses on the differences from the other embodiments.

The above description is only for the preferred embodiment of the present invention, and is not intended to limit the scope of the present invention. Any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention shall fall within the protection scope of the present invention.

Claims (11)

1. An automatic roll forging forming production line comprises a hydraulic roll forging machine (7) and an induction heating furnace (3); the method is characterized in that: the hydraulic roll forging machine (7) and the induction heating furnace (3) are arranged in parallel at a transverse interval; the induction heating furnaces (3) are provided with a plurality of induction heating furnaces, and adjacent induction heating furnaces (3) are transversely concentrically connected in series through the transmission rollers (3-2) to form a continuous through type induction heating furnace group; a clamping roller (3-1) is arranged at the feeding end part of the induction heating furnace (3); a feeding roller (2) is concentrically arranged with the clamping roller (3-1) in a collinear way; a storage rack (1) is arranged perpendicular to the conveying direction of the feeding roller (2); the discharge end of the induction heating furnace (3) at the tail end is concentrically connected with one end of a discharge roller (4); a positioning oil cylinder (4-1) is concentrically arranged at the other end of the discharging roller (4); the material receiving roller (8) is arranged on one side of the discharging roller (4) and is parallel to the discharging roller (4) at intervals, and the hydraulic roll forging machine (7) and the forging manipulator (6) which are concentric are arranged on the other side of the discharging roller (4); a forging station is arranged between the hydraulic roll forging machine (7) and the forging manipulator (6), and the forging station and the forging rotating working area (11) are simultaneously used; the longitudinal vertical crossing forging station, the discharge roller (4) and the receiving roller (8) are provided with a longitudinal crossing type feeding and discharging rotating mechanism (5) of the truss manipulator, and the longitudinal crossing type feeding and discharging rotating mechanism (5) of the truss manipulator drives a workpiece to longitudinally displace, vertically lift and rotate for 360 degrees; a stepping slow cooling chain plate roller way (9) is concentrically arranged at the discharge end of the receiving roller (8); a blanking roller (10-1) is concentrically arranged at the transmission tail end of the stepping slow cooling chain plate roller way (9); and a stacking device (10) is vertically connected with the blanking roller (10-1).

2. The automated roll forging line of claim 1, wherein: the control method comprises a full-automatic control mode, a pure manual control mode and a step-by-step semi-automatic control mode.

3. The automated roll forging line of claim 1, wherein: the storage racks (1) are used for parallelly placing workpieces which are hoisted in place one by one at intervals; the storage rack (1) is composed of a plurality of independent supports (101) which are vertically arranged at equal intervals; the upper supporting surface of the independent bracket (101) contacting with the workpiece is provided with a transmission chain plate (102); the conveying chain plates (102) are used for vertically conveying materials.

4. The automated roll forging line according to claim 1 or 3, wherein: the material storage rack (1) is provided with a feeding button; when the feeding roller (2) detects that no material exists but the material exists on the material storage rack (1), the material loading button is pressed down, and the material storage rack (1) automatically vertically conveys the workpiece on the material storage rack to the central position of the feeding roller (2) and then stops conveying; and when the induction heating furnace stops, the feeding roller (2) starts to start after detecting that the workpiece is in place and transversely conveys the workpiece to a furnace mouth of the first induction heating furnace (3).

5. The automated roll forging and forming production line according to claim 1, wherein: the clamping roller (3-1) and the conveying roller (3-2) are identical in structure and different in function, the clamping roller (3-1) is used for clamping and biting workpieces, and the conveying roller (3-2) is used for realizing continuous conveying of the workpieces; the holding roll (3-1) has two or more closely adjacent rolls, and the conveying roll (3-2) has one roll; when the front workpiece is completely separated from the clamping roller (3-1), the clamping roller (3-1) detects that no material exists; the feeding roller (2) starts to automatically feed the rear workpiece so as to realize the continuous feeding of the induction heating furnace (3); wherein the rotating speed and the clamping force of the clamping roller (3-1) are always the same as those of the transmission roller (3-2).

6. The automated roll forging line according to claim 1 or 5, wherein: the clamping roller (3-1) is provided with a displacement sensor; when the displacement sensor detects that the workpiece is transmitted to a positioning displacement value between an upper roller and a lower roller of the clamping roller (3-1), the roller body of the clamping roller (3-1) is automatically ejected out to bite the workpiece, and the clamping roller (3-1) clamps the workpiece according to a set rotating speed and moves in the induction heating furnace (3) at a constant speed to feed.

7. The automated roll forging line of claim 1, wherein: the discharging roller (4) and the feeding roller (2) are both active conveying roller ways; the discharging roller (4) and the feeding roller (2) have the same structure and are concentric and collinear; and after the workpiece reaches the fixed position of the discharge roller (4), triggering a working signal of a positioning oil cylinder (4-1), and ejecting the positioning oil cylinder (4-1) according to a set numerical value to adjust the central position of the discharged workpiece, so that the center of the discharged workpiece is always positioned under the clamping station of the feeding and discharging rotating mechanism (5) of the longitudinal crossing type truss manipulator.

8. The automated roll forging line of claim 1, wherein: the stepping slow cooling chain plate roller way (9) is an active chain plate transmission mechanism; the receiving roller (8) has the same structure as the stepping slow cooling chain plate roller way (9); the total length of a continuous roller way consisting of the stepping slow cooling chain plate roller way (9) and the receiving roller (8) is at least three times that of a formed workpiece; the outer side of the whole transmission direction of the stepping slow cooling chain plate roller way (9) is matched with a heat insulation cover (9-1).

9. The automated roll forging and forming production line according to claim 1, wherein: the blanking roller (10-1) is of an unpowered blanking roller structure; the stacking device (10) is provided with a stacking manipulator and a blanking frame (10-2); the stacking manipulator is used for clamping a workpiece which is formed in place on the blanking roller (10-1) and vertically transferring the workpiece to the blanking frame (10-2); the blanking frame (10-2) parallelly places the formed workpieces transferred in place by the stacking manipulator at intervals one by one.

10. The automated roll forging line of claim 1, wherein: the forging manipulator (6) has the functions of clamping, loosening, advancing, retreating and clamping and rotating.

11. The automated roll forging line according to claim 1 or 7, wherein: the feeding and discharging rotating mechanism of the longitudinal crossing type truss manipulator is provided with a material grabbing manipulator (5-2), and the material grabbing manipulator (5-2) has the functions of linear displacement along the horizontal direction, linear lifting along the vertical direction and 360-degree rotation in the horizontal plane.

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