CN116749582A - Workpiece production line control system and control method - Google Patents
Workpiece production line control system and control method Download PDFInfo
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- CN116749582A CN116749582A CN202311040784.6A CN202311040784A CN116749582A CN 116749582 A CN116749582 A CN 116749582A CN 202311040784 A CN202311040784 A CN 202311040784A CN 116749582 A CN116749582 A CN 116749582A
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- 238000007493 shaping process Methods 0.000 claims description 51
- 238000012545 processing Methods 0.000 claims description 47
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- 229910000797 Ultra-high-strength steel Inorganic materials 0.000 description 6
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B30—PRESSES
- B30B—PRESSES IN GENERAL
- B30B15/00—Details of, or accessories for, presses; Auxiliary measures in connection with pressing
- B30B15/26—Programme control arrangements
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D19/00—Flanging or other edge treatment, e.g. of tubes
- B21D19/08—Flanging or other edge treatment, e.g. of tubes by single or successive action of pressing tools, e.g. vice jaws
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D35/00—Combined processes according to or processes combined with methods covered by groups B21D1/00 - B21D31/00
- B21D35/002—Processes combined with methods covered by groups B21D1/00 - B21D31/00
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D37/00—Tools as parts of machines covered by this subclass
- B21D37/08—Dies with different parts for several steps in a process
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Shaping Metal By Deep-Drawing, Or The Like (AREA)
Abstract
The application relates to a control system and a control method of a workpiece production line, wherein the control system of the workpiece production line comprises: a main control console; a first subsystem disposed on the first punch, comprising: the first step controller, the first positioning error controller and the first tool feedback controller; a second subsystem disposed on the second punch, comprising: the second stepping controller, the second positioning error controller and the second tooling feedback controller; the first positioning error acquisition device is arranged on the first punching machine; the second positioning error acquisition device is arranged on the second punching machine; a first pressure sensor disposed on the first punch; a second pressure sensor disposed on the second punch; and a conveying mechanism configured to convey the workpiece between the first punch and the second punch. The production line control system can better control production and obtain products with higher precision.
Description
Technical Field
The application relates to the field of control and manufacturing control, in particular to a workpiece production line control system and a control method.
Background
With the development of the automobile industry, the problems of high reinforcement, light weight and safety of the automobile body are important development directions of the current automobile technology development. The ultra-high strength steel plate (steel plate with tensile strength of 980-1180 mpa) can reduce the weight of the automobile body and improve the structural strength and the energy absorption capacity of the automobile body, so that the ultra-high strength steel plate is widely applied to automobiles. The application of high-strength steel/ultra-high-strength steel plates has led to the development of processing techniques in the direction of high strength/high quality.
However, the workpiece of the high-strength steel/ultra-high-strength steel plate has the characteristics of thick material, high hardness, easiness in cracking, large rebound quantity and the like, the flow and the molding size of the molding material are difficult to control in the production process, and high requirements are placed on the control of a production line. These are all technical problems to be solved in the art.
Disclosure of Invention
Aiming at the technical problems in the prior art, the invention provides a workpiece production line control system, wherein the workpiece production line comprises a first punch press and a second punch press, a plurality of different stations are respectively arranged on the first punch press and the second punch press, and the workpiece production line control system comprises: a main control console; a first subsystem disposed on the first punch press, comprising: a first stepper controller configured to control transfer of the workpiece between different stations in the first punch press, a first positioning error controller configured to obtain a positioning error of the workpiece, and a first tooling feedback controller configured to obtain the workpiece clamping condition; a first positioning error acquisition device disposed on the first punch and configured to obtain an actual position of the workpiece and communicate to the first positioning error controller; the first pressure sensor is arranged on the first punch and is in feedback control communication connection with the first tool, and is used for obtaining the clamping condition of the workpiece; a second subsystem disposed on the second punch press, comprising: a second step controller configured to control transfer of the workpiece between different stations in the second punch press, a second positioning error controller configured to obtain a positioning error of the workpiece, and a second tooling feedback controller configured to obtain the workpiece clamping condition; a second positioning error acquisition device disposed on the second punch and configured to acquire an actual position of the workpiece and communicate to the second positioning error controller; the second pressure sensor is arranged on the second punching machine and is in feedback control communication connection with the second tool and is used for obtaining the clamping condition of the workpiece; and a conveying mechanism configured to convey the workpiece between the first punch and the second punch.
According to the workpiece production line control system, the first continuous die is arranged on the first punch press, the second continuous die is arranged on the second punch press, the first continuous die and the second continuous die further comprise a plurality of areas, and each area further comprises different processing procedures.
A workpiece production line control system as described above, the machining process including, but not limited to: blanking, pretreatment, blanking, flanging, transferring, feeding, punching, shaping, side punching, discharging, bending, deep drawing and three-dimensional pressing.
A workpiece production line control system as described above, the workpiece production line further comprising: and the third punch is provided with a third progressive die.
In the workpiece production line control system, the first positioning error acquisition device and the second positioning error acquisition device are high-definition image acquisition devices or laser sensors.
According to another aspect of the present application, there is provided a workpiece production line control method, including: the first stepping controller receives the instruction of the main control console and controls the workpiece to be transferred and processed between different stations of the first punch; when the workpiece is transferred between different stations, the first error controller receives the instruction of the main control console, controls the first positioning error acquisition device to acquire the actual position of the workpiece, judges the first positioning error of the workpiece, and receives the instruction of the main control console and the information of the first pressure sensor to judge the first clamping condition of the workpiece; after the workpiece is processed in the first punch, the conveying mechanism receives the instruction of the main control console and transfers the workpiece to the second punch; the second stepping controller receives the command of the main control console and controls the workpiece to be transferred and processed between different stations of the second punch; and when the workpiece is transferred between different stations, the second error controller receives the instruction of the main control console, controls the second positioning error acquisition device to acquire the actual position of the workpiece and judges the second positioning error of the workpiece, and the second tooling feedback controller receives the instruction of the main control console and receives the information of the second pressure sensor to judge the second clamping condition of the workpiece.
In the control method, the first error controller notifies the first step controller to adjust the position of the workpiece in response to the first positioning error of the workpiece being greater than a preset threshold.
In the control method, when the first clamping condition of the workpiece is not clamped, the first tooling feedback controller informs the first stepping controller to pause processing, and an alarm is sent to request manual intervention.
In the control method, the second error controller notifies the second step controller to adjust the position of the workpiece in response to the second positioning error of the workpiece being greater than a preset threshold.
In the control method, when the second clamping condition of the workpiece is not clamped, the second tooling feedback controller informs the second stepping controller to pause processing, and an alarm is sent to request manual intervention.
The control system of the application can flexibly distribute impulse force, can prevent error accumulation, can better control production and obtain products with higher precision, and can release the accumulated error before the next punch is processed by adding a conveying mechanism between two punches and repositioning the punch before the next punch is processed, thereby not affecting the timeliness of processing and improving the precision of forming size.
Drawings
Preferred embodiments of the present invention will be described in further detail below with reference to the attached drawing figures, wherein:
FIG. 1 is a schematic diagram of an ultra-high strength board processing line control system according to one embodiment of the invention;
FIG. 2 is a schematic view of an ultra-high strength board processing line according to one embodiment of the invention;
FIG. 3 is a schematic view of a first progressive die structure according to an embodiment of the present invention;
FIG. 4 is a first progressive die top view in accordance with one embodiment of the invention;
FIG. 5 is a cross-sectional view taken along the direction A-A in FIG. 4;
FIG. 6 is a sectional view taken in the direction B-B of FIG. 4;
FIG. 7 is a schematic view of a first progressive die lower die holder in accordance with one embodiment of the present invention;
FIG. 8 is a schematic diagram of a second progressive die structure in accordance with one embodiment of the present invention;
FIG. 9 is a second progressive die top view in accordance with one embodiment of the invention;
FIG. 10 is a cross-sectional view taken in the direction C-C of FIG. 9;
FIG. 11 is a schematic diagram of a second progressive die lower die holder in accordance with one embodiment of the present invention; and
fig. 12 is a control flow chart of an ultra-high strength board processing line according to an embodiment of the present invention.
Detailed Description
For the purpose of making the objects, technical solutions and advantages of the embodiments of the present invention more apparent, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention, and it is apparent that the described embodiments are some embodiments of the present invention, but not all embodiments of the present invention. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
In the following detailed description, reference is made to the accompanying drawings, which form a part hereof, and in which is shown by way of illustration specific embodiments of the application. In the drawings, like reference numerals describe substantially similar components throughout the different views. Various specific embodiments of the application are described in sufficient detail below to enable those skilled in the art to practice the teachings of the application. It is to be understood that other embodiments may be utilized or structural, logical, or electrical changes may be made to embodiments of the present application.
Because the workpieces of the high-strength steel/ultra-high-strength steel plates have the characteristics of thick material, high hardness, easiness in cracking, large rebound quantity and the like, the cold stamping process is difficult to produce the high-strength steel/ultra-high-strength steel plates, the hot forming process is still generally adopted at home and abroad at present, the construction efficiency is low, the energy consumption is high, the equipment investment is large, the production period is long, the environment is polluted, and the carbon emission is high.
Therefore, the application discloses a novel ultra-high-strength plate processing production line, a control system and a control method thereof, which can perform cold stamping processing on the ultra-high-strength plate, accurately control the flow and the positioning of a forming material, timely obtain feedback of each station tool, achieve the accurate control of forming size, realize the stamping processing of the ultra-high-strength plate, and can be widely applied to the processing of automobile parts, aviation parts and the like.
The solution disclosed in the present application is different from the prior art from the mold design stage of the production line. The modularized database and advanced software Autoform and Dynaform are utilized to carry out fine analysis on the process digital-analog, complex internal shape and external shape can be decomposed into simple male die and female die shape, a plurality of working procedures are formed through segmentation and successive processing, and then the working procedures can be dispersed on a plurality of continuous stations. And a vacancy can be arranged in the concentrated working procedure area, so that the problem that the wall thickness of the male die and the wall thickness of the female die are too small is avoided, the stress state of the male die and the concave die is changed, and the die strength of the production line is improved. Further, the inventors found that the accumulated length according to the magnitude of the impact force and the process has an important influence on the precise control of the molding dimension. Therefore, a plurality of working procedures such as pretreatment, shaping, blanking, flanging, bending, deep drawing, three-dimensional pressing and the like are distributed on two or more punching machines, so that the punching force can be flexibly distributed, the accumulation of errors can be prevented, the production control of a production line can be better carried out, and products with higher precision can be obtained. Although a conveying mechanism needs to be added between two punching machines, the adding of the conveying mechanism does not affect the timeliness of processing, but can improve the accuracy of the forming size due to the fact that the conveying mechanism needs to be repositioned before the next punching machine is processed and errors accumulated before releasing.
In some embodiments, the ultra-high strength plate processing production line of the application utilizes special materials to wrap and protect the die forming bow, can effectively eliminate the lateral force generated by the stamping of the die, and is beneficial to prolonging the service life of the die and improving the quality of products.
In some embodiments, the molding bow of the die in the ultra-high strength plate processing production line adopts a carbide coating treatment (Thermal Diffusion Carbide Coating Process) by a super thermal diffusion method, namely super TD heat treatment, so that a seepage layer can be formed on the surface of the molding bow, thereby being beneficial to improving the hardness of the surface of the molding bow and prolonging the service life of the die.
In some embodiments, the ultra-high strength plate processing production line can effectively improve the production efficiency, improve the product quality, greatly improve the service life of the die, fill the blank of the ultra-high strength plate cold stamping forming technology in the domestic and foreign industries and is a technical innovation for solving the problem of light weight and improving the safety of automobiles and new energy automobiles by reducing the turnover and repeated positioning processes of a plurality of dies, configuring high-precision internal and external guiding, accurate distance systems and other industrial settings.
The technical scheme of the application is further described by the specific embodiments. It should be understood by those skilled in the art that the following descriptions are only for convenience in understanding the technical solutions of the present application and should not be used to limit the scope of the present application.
FIG. 1 is a schematic diagram of an ultra-high strength board processing line control system according to one embodiment of the application. As shown, the production line control system 10 includes a main control console 11, a first punch 12, a second punch 13, and a transport mechanism 17 between the first punch 11 and the second punch 12. The first punch press 12 has a first sub-control system including a first stepper controller 14, a first positioning error controller 15, and a first tooling feedback controller 16. The first step controller 14, the first positioning error controller 15, and the first tool feedback controller 16 communicate with the main control console 11, transmit an operating state to the main control console 11, and receive an instruction from the main control console 11 to adjust the first punch press 12. The second punch 13 has a second sub-control system including a second stepper controller 24, a second positioning error controller 25, and a second tooling feedback controller 26. The second step controller 24, the second positioning error controller 25, and the second tool feedback controller 26 communicate with the main control console 11, transmit the operating state to the main control console 11, and receive the instruction from the main control console 11 to adjust the second punch 13. The real-time working conditions of the first punch 12 and the second punch 13 can be known through the main control console 11, and the two can be respectively adjusted.
Fig. 2 is a schematic view of an ultra-high strength board processing line according to an embodiment of the present invention. As shown, the production line includes: the first punch 12 and the second punch 13 and the super high strength plate cold stamping die 100 (may be simply referred to as "cold stamping die" or "die"), wherein the super high strength plate cold stamping die 100 is provided on the first punch and the second punch. The ultra-high-strength plate cold stamping die 100 may include a first continuous die 110 and a second continuous die 120. The first continuous die 110 is disposed on the first punch 12, the second continuous die 120 is disposed on the second punch 13, and the ultra-high-strength plate can be continuously formed by punching through the first continuous die 110 and the second continuous die 120.
In this embodiment, the first continuous die 110 and the second continuous die 120 are progressive dies, and may be composed of a plurality of stations, each station is sequentially associated to complete different processing, and a series of different punching processes are completed in one stroke of the punching machine, so as to form a processing production line of the ultra-high-strength plate. The first and second stepper controllers 14 and 24 are used to control the transfer of workpieces in the progressive die between different stations. The first step controller 14 and the second step controller 24 can realize high-precision position control of the workpiece, thereby ensuring the accuracy of the molding size.
In an embodiment, the working process of the workpiece includes: blanking, pretreatment, flanging, punching, shaping, side punching and the like. The pretreatment and flanging processes are arranged in a first continuous die, and the punching, shaping and side punching processes are arranged in a second continuous die according to different punching forces and process lengths. Therefore, the first punching machine also comprises a blanking area for cutting the ultra-high strength plate; the pretreatment area and the flanging area are used for pretreatment and flanging procedures. After the flanging process of the first punch press, a transfer area can be further increased for transferring the workpiece after the preliminary processing by the conveying mechanism. A feed zone may be included prior to the punching process of the second punch and may be used to receive and position the workpiece. The second punching machine also comprises a punching area, a shaping area and a side punching area which are used for punching, shaping and side punching procedures. A discharge zone may also be included on the second punch for removing the processed workpiece.
In some embodiments, a positioning error acquisition device (e.g., a high definition image acquisition device or a laser sensor) is included on the first punch 12 between the preprocessing and flanging processes to acquire the actual position of the workpiece. The first positioning error controller 15 receives the actual position of the workpiece from the positioning error acquisition means and compares it with a predetermined position, thereby obtaining a positioning error of the workpiece. Further, the first positioning error controller 15 may take no action if the error is less than a predetermined threshold. If the error is greater than the predetermined threshold, the first positioning error controller 15 notifies the first step controller 14 to adjust the position of the workpiece, ensuring the machining accuracy.
In one embodiment, a high definition image acquisition device is used to take a photograph of the workpiece, and the contours of the workpiece in the photograph are identified by a trained artificial intelligence model. Since the other positions than the workpiece in the photograph remain unchanged, the actual position of the workpiece can be easily recognized. In another embodiment, the position of the workpiece from the laser sensor is measured directly with a millimeter scale laser sensor, thereby obtaining the actual position of the workpiece. Because the laser sensor has higher cost, the high-definition image acquisition device can achieve the same or even higher precision, and has stronger adaptability. Therefore, a high definition image acquisition device is used in the preferred embodiment.
In one embodiment, a tool is required to clamp the workpiece during the flanging operation on the first punch 12. In this process, deviations occur with a small probability, which result in the workpiece not being clamped. A pressure sensor may be added to the tool to ensure that the workpiece is clamped. The pressure sensor is connected to a first tooling feedback controller 16. If the first tool feedback controller 16 finds that the workpiece is not clamped, the first stepper controller 14 is notified to pause the machining process and an alarm is issued requesting manual intervention.
Similarly, in some embodiments, a positioning error acquisition device (e.g., a high definition image acquisition device or a laser sensor) is included on the second punch 13 between the shaping process and the side-punching process to acquire the actual position of the workpiece. Generally, the punching process has less influence on the positioning of the part, and positioning errors do not need to be acquired. The second positioning error controller 25 receives the actual position of the workpiece from the positioning error acquisition means and compares it with a predetermined position, thereby obtaining a positioning error of the workpiece. Further, the second positioning error controller 25 may take no action if the error is smaller than a predetermined threshold. If the error is greater than the predetermined threshold, the second positioning error controller 25 notifies the second step controller 24 to adjust the position of the workpiece, ensuring the accuracy of the machining.
In one embodiment, a high definition image acquisition device is used to take a photograph of the workpiece, and the contours of the workpiece in the photograph are identified by a trained artificial intelligence model. Since the other positions than the workpiece in the photograph remain unchanged, the actual position of the workpiece can be easily recognized. In another embodiment, the position of the workpiece from the laser sensor is measured directly with a millimeter scale laser sensor, thereby obtaining the actual position of the workpiece. Because the laser sensor has higher cost, the high-definition image acquisition device can achieve the same or even higher precision, and has stronger adaptability. Therefore, a high definition image acquisition device is used in the preferred embodiment.
In one embodiment, the workpiece is clamped by a tool in the shaping process on the second punch 13. In this process, deviations occur with a small probability, which result in the workpiece not being clamped. And a pressure sensor is added on the tool to ensure that the workpiece is clamped. The pressure sensor is connected to a second tooling feedback controller 26. If the second tool feedback controller 26 finds that the workpiece is not clamped, the second stepper controller 24 is notified to halt the machining process and an alarm is sent to request manual intervention.
In some embodiments, a conveying mechanism 17 is disposed between the first punch 12 and the second punch 13 for conveying the work piece between the first progressive die 110 and the second progressive die 120. In some embodiments, the transport mechanism includes, but is not limited to: robot, conveyor belt, etc.
According to the technical scheme, different processing procedures performed in different areas are distributed to two or more than two punching machines according to different impulsive forces and procedure lengths, continuous processing of workpieces can be realized, and high fluidity of forming materials and high precision of forming sizes can be maintained. And by arranging different processing procedures and arranging the processing procedures on two or more punching machines, the punching process can be more flexible, and the punching force can be better distributed, so that the punching force is effectively saved, and the punching force is prevented from being unbalanced. The conveying mechanism conveys workpieces among different punching machines, so that the efficiency of punching forming is not affected, and the matching of positioning accuracy among different processing procedures is improved.
In some embodiments, more areas may also be included on the first continuous die 110 and/or the second continuous die 120 to enable more functionality. The present embodiment is merely illustrative of the present application, but is not limited to the process and carding of the process. In some embodiments, the processing line may further include a third punch including a third progressive die thereon. The technical scheme of the application is not limited to two punching machines.
The structure of the ultra-high-strength plate processing line of the present application will be described in detail below, and as will be understood by those skilled in the art, the punch press only provides power and control, and the specific structure of the line depends on the structure of the progressive die on the punch press, and the structure of the progressive die will be described in detail below.
Fig. 3 is a schematic view of a first progressive die structure according to an embodiment of the present application. Fig. 4 is a first progressive die top view in accordance with one embodiment of the application. Fig. 5 is a sectional view taken along the direction A-A in fig. 4. Fig. 6 is a sectional view in the direction B-B of fig. 4. Fig. 7 is a schematic view of a first progressive die lower die holder according to an embodiment of the application.
As shown, the first continuous die 110 may control the ultra-high-strength plate continuous stamping process, which includes a first upper die holder 210 and a first lower die holder 220. The first upper die base and the first lower die base are respectively connected with the first punching machine and are matched with each other to punch the ultrahigh-strength plate.
In some embodiments, the first upper die holder 210 and/or the first lower die holder 220 include a pretreatment structure and a flanging structure, which can correspondingly perform pretreatment and flanging on the ultra-high-strength plate. When carrying out the turn-ups shaping to the super high-strength board, especially not turn-ups one side shape is complicated, can punch out the super high-strength board in advance, processes out the turn-ups and does not turn-ups the boundary between to be convenient for follow-up turn-ups process, be favorable to the turn-ups process, and can also effectually prevent that the super high-strength board from kick-backing. In some embodiments, the ultra-high strength plate is introduced by a first continuous die that controls the ultra-high strength plate to be introduced into the pretreatment structure first, then introduced into the first flanging structure by the pretreatment structure, and introduced into the second continuous die after exiting the first continuous die by the flanging structure. In some embodiments, other regions (not shown) may also be included on the first upper die base 210 and/or the first lower die base 220. For example: the blanking area can be used for cutting out the ultrahigh-strength plate required by the part through stamping.
The pretreatment structure and the flanging structure will be described in detail below by using the first lower die holder, and as understood by those skilled in the art, the lower die holder and the upper die holder are mutually matched, and the structure of the upper die holder can be obtained according to the lower die holder, which is not described herein.
Referring to fig. 7, the first lower die holder 220 includes pre-processing forming bows 221 and 222 and flanging forming bows 223 and 224, the pre-processing forming bows 221 and 222 can be oppositely arranged at two sides of the first lower die holder, the flanging forming bows 223 and 224 are oppositely arranged at two sides of the first lower die holder, the pre-processing forming bows 221 and the flanging forming bows 223 are in the same straight line, the pre-processing forming bows 223 and the flanging forming bows 224 are in the same straight line and are parallel to the straight lines of the pre-processing forming bows 221 and the flanging forming bows 223, so that a workpiece can be continuously punched and formed in different areas, and the two pre-processing forming bows and the flanging forming bows are oppositely arranged at two sides, so that the side force of punching can be effectively offset each other, the die can be protected, and the service life of the die can be prolonged.
In some embodiments, the material of the pre-treatment forming bow and the flanging forming bow can be high alloy tool steel, high-speed steel or hard alloy, and the material is manufactured by adopting advanced processing methods such as slow wire cutting processing, forming grinding, coordinate boring, coordinate grinding and the like, so that the roughness of the surface of the forming bow can be effectively ensured, and the precision of the surface of a workpiece is ensured.
Because the ultra-high-strength plate has larger hardness, when the ultra-high-strength plate is stamped, the surface stress of the forming bow is larger, the forming bow is extremely easy to damage, and the service life of the die is seriously influenced. In some embodiments, the surfaces of the pre-treatment forming bow and the flanging forming bow can be subjected to super TD heat treatment, which has higher hardness and wear resistance with excellent binding force; the self-lubricating, seizure resistance, high-temperature oxidation resistance and corrosion resistance are strong, the strength and hardness of the surface of a forming bow can be effectively improved, the die is prevented from being damaged by stamping of the ultra-high strength plate, the service life of the die can be effectively prolonged, the product quality can be effectively improved, the production cost is reduced, meanwhile, the maintenance times of the die can be reduced, the operation environment is improved, and powerful guarantee is provided for safe production. In some embodiments, the super TD heat treatment may cause the contoured arch surface to form a percolating layer. In some embodiments, the vickers hardness of the strike layer may reach HV2600-3300. In some embodiments, the super TD heat treatment technique can be repeatedly applied to the same part of the die for a plurality of times, thereby solving the problem of the service life of the die.
In some embodiments, the first lower die holder 220 may further include movable blocks 225 and 226, which are respectively disposed in the flanging forming bows 223 and 224 and may be connected with a nitrogen spring to move in the flanging forming bows, so as to cooperate with the upper die holder to clamp the flanged workpiece, prevent the workpiece from being offset, be beneficial to increasing the yield of the flanging, improve the positioning accuracy of the flanging, and remove the workpiece from the flanging forming bows after the flanging is completed, so as to facilitate the subsequent transfer of the workpiece.
In some embodiments, the first lower die holder 220 may further include pressure sensors 205 and 206, which are respectively disposed on the movable blocks 225 and 226, and may be used to determine whether the workpiece is clamped in place when the movable blocks 225 and 226 are matched with the upper die holder to clamp the workpiece, so that stability and accuracy of subsequent flanging of the workpiece may be ensured, which is beneficial to improving production quality. In some embodiments, a plurality of pressure sensors may be included on each movable block, so that the workpiece can be more comprehensively clamped in place. In some embodiments, the pressure sensor may also be disposed on the first upper die base.
In some embodiments, the first lower die holder 220 may further include a positioning error obtaining device 207, which may be disposed between the preprocessing structure and the flanging structure, may be used to obtain an actual position of the workpiece, and may generate relevant information to a positioning error controller, so that the actual position of the workpiece may be obtained, so as to ensure processing accuracy of the workpiece. In some embodiments, the positioning error acquisition device 207 may be a high definition image acquisition device (e.g., a camera, video camera, etc.) that uses a photograph taken of the workpiece to determine its actual location. In some embodiments, the number of the positioning error obtaining devices may be plural, so that the actual position of the workpiece may be obtained by combining the plural positioning error obtaining devices, which is beneficial to improving the positioning accuracy of the workpiece, ensuring the processing accuracy, and improving the working efficiency. In some embodiments, the positioning error acquisition means may also be a laser sensor.
In some embodiments, the ultra-high strength plate has higher strength, and the ultra-high strength plate has higher rebound and is easy to generate lateral force during flanging, and although the two flanging forming bows are oppositely arranged to offset part of the lateral force, the die is still influenced by the larger lateral force. The first lower die holder 220 may further include wrapping blocks 227 and 228 disposed on the outer side of the flanging die bow to effectively counteract the lateral forces generated by the flanging.
In some embodiments, the wrap block is generally similar to a "bowl" that wraps around and around the bottom of the flanging die. In some embodiments, the wrap-block may be milled into a single piece, which may increase its overall strength and stability. In some embodiments, the bottom of the parcel block includes a plurality of through holes that can be used for the movable block to connect with the nitrogen spring, as well as for the guiding of the movable block movement. In some embodiments, the hardness of the wrap blocks is lower than the hardness of the flanging die bow, so that the lateral forces generated by the flanging can be effectively counteracted.
In some embodiments, the material of the wrap block may be 45 gauge steel, stainless steel, 304 steel, etc., and in some embodiments the thickness of the wrap block wrapping the longer side of the flanging die bow may be 50-80cm. In some embodiments, the longer side of the wrap block wrapped around the flanging die may also include a plurality of stops 229, which may increase the strength of the wrap block. In some embodiments, the distance between the side of the stop remote from the wrapper and the inside of the wrapper is 1.5-2 times the height of the stop. In some embodiments, the height of the stop may be 140-160cm. In some embodiments, the stop 229 and the wrapping block may further include an adjusting piece (not shown in the drawings) therebetween, which may be used to adjust a distance therebetween, and when the wrapping block is inclined outward due to the lateral force, the support for the flanging die bow cannot be provided, and the wrapping block may be adjusted by the adjusting piece so that the wrapping block is fitted with the flanging die bow. In some embodiments, the wrap blocks 227 and 228 wrap the shorter sides of the flanging die in contact with each other so that the side forces of the flanging die can be offset from each other.
In some embodiments, the first lower die holder 220 may further include limit guide grooves 201-204, which are respectively disposed near 4 corners of the first lower die holder 220, which correspond to the first upper die holder, and may guide the first lower die holder and the first upper die holder to punch each other, and may limit the positions of the first lower die holder and the first upper die holder to punch, preventing the work piece from being excessively damaged by the punching.
Fig. 8 is a schematic diagram of a second progressive die structure according to an embodiment of the invention. Fig. 9 is a second progressive die top view in accordance with one embodiment of the invention. Fig. 10 is a sectional view taken along the direction C-C in fig. 9. FIG. 11 is a schematic diagram of a second progressive die lower die holder according to one embodiment of the invention.
As shown, the second progressive die 120, which can control the continuous stamping of the ultra high strength plate workpiece, includes a second upper die holder 710 and a second lower die holder 720. The second upper die holder and the second lower die holder are respectively connected with the second punching machine and are matched with each other to punch the ultrahigh-strength plate.
In some embodiments, the second upper die holder 710 and/or the second lower die holder 720 include a punching area, a shaping area, and a side punching area, and the ultra-high strength plate may be correspondingly punched, shaped, and side punched. After the flanging forming is completed on the ultra-high-strength plate, the workpiece has certain rebound due to high strength of the ultra-high-strength plate, the flanging is required to be shaped, the rebound is eliminated, and the stress is released by punching the workpiece in advance in order to avoid the influence of punching on the rebound. In some embodiments, after the ultra-high-strength plate workpiece enters the second continuous die from the first continuous die, the second continuous die controls the ultra-high-strength plate with the flanging to be finished to enter the punching structure, enter the shaping structure from the punching structure, enter the side punching structure from the shaping structure, and leave the second continuous die from the side punching structure. In some embodiments, other regions (not shown) may also be included on the second upper die holder 710 and/or the second lower die holder 720. For example: the separating area can slide the workpiece out for collection through stamping.
The structure of the punching area, the shaping area and the side punching area will be described in detail by using the second lower die holder, and as understood by those skilled in the art, the lower die holder and the upper die holder are mutually matched, and the structure of the upper die holder can be obtained according to the lower die holder, which is not described herein.
Referring to fig. 11, the second lower die holder 720 is also relatively provided with the same structure in the same region, and only one of the structures will be described herein, and the description will not be repeated.
In some embodiments, the second lower die holder 720 includes a punching structure that includes a plurality of positioning blocks 721 that can be used to define the workpiece and that can cooperate with the second upper die holder to punch the workpiece. In some embodiments, the punching structure may further include a pad 722 disposed between the positioning blocks and between the workpiece and the second die holder, which may prevent the punch from damaging the second die holder during punching, and may also support the workpiece to prevent the punch from damaging the workpiece during punching. In some embodiments, the punch may be made of powder metallurgy die steel, which may effectively improve the strength of the punch, increase the chipping resistance of the punch, and may punch ultra-high strength plates.
In some embodiments, the second lower die holder 720 further includes a shaping structure that includes shaping blocks 723 and 724 and a backing block 725. The backing block 725 is disposed on the second lower die holder, and may be used for setting off a workpiece to be shaped, and shaping blocks 723 and 724 are disposed on two sides of the backing block 725, respectively, and may clamp the workpiece, eliminate rebound of the workpiece, make it reach a predetermined angle of flanging, and shape the workpiece.
In some embodiments, the junction of the backing block 725 and the second die holder is concave inward, the workpiece to be shaped is back-buckled on the backing block, and the side of the shaping block, which is close to the backing block, comprises a protrusion and can be matched with the concave of the backing block, so that the workpiece can be pressed inward to shape.
In some embodiments, the second upper die holder 710 may further include a presser block 711 that may press the workpiece against the pad 725, preventing other portions from being deformed by force when shaping the flange. In some embodiments, the presser block is movable between the dies in conjunction with the nitrogen spring, so that other portions of the workpiece can be pressed against the pad prior to shaping the flange.
In some embodiments, the shaping structure may further include a pressure sensor 707, which may be disposed on the pad 725, and may be configured to determine whether the workpiece is clamped in place when the pressing block is matched with the pad to clamp the workpiece, so as to ensure stability and precision of shaping the workpiece subsequently, which is beneficial to improving production quality. In some embodiments, the pad may further include a plurality of pressure sensors thereon, so that the workpiece may be more fully held in place. In some embodiments, the pressure sensor may also be disposed on the presser block.
In some embodiments, the shaping structure further includes first driving blocks 726 and 727, which are disposed on sides of the shaping blocks 723 and 724, respectively, that are remote from the pad 725, and may be used to drive the shaping blocks toward the pad. In some embodiments, the surfaces of the first drive blocks 726 and 727 on the side remote from the pads are beveled, by which the drive blocks can be urged toward the pads. In some embodiments, the second upper die base 710 may also include second drive blocks 712 and 713, which are secured to the second upper die base, and which, like the first drive blocks 726 and 727, may be configured to drive the first drive blocks 726 and 727 toward the pads. In some embodiments, the shaping block may be fixedly coupled to the first drive block.
In some embodiments, the shaping structure may further include a reset structure (not shown) disposed between the first drive blocks 726 and 727 and the second lower die base, which may be used to reset the first drive blocks 726 and 727 so that the shaped workpiece may be removed. In some embodiments, the reset structure may also be disposed between the shaping block and the second lower die holder. In some embodiments, the shaping structure may further include tool holders 728 and 729, which are disposed on a side of the first driving block away from the shaping block, and may define a position of the second driving block, so that the second driving block drives the first driving block, and may also protect the second driving block from damage caused by a reaction force of the driving.
In some embodiments, an adjusting piece (not shown in the figure) may be further included between the shaping block and the second lower die holder or the first driving block, and may be used to adjust a distance between the shaping block and the second lower die holder or the first driving block, so that a relative height between the shaping block and the pad may be adjusted, and a shaping angle of the workpiece flanging may be adjusted. In some embodiments, the shaping block may include a plurality of adjusting holes 701, which may be used to connect the shaping block with the second lower die base or the first driving block, and may further adjust the position of the shaping block, so as to adjust the relative distance between the shaping block and the pad, and adjust the shaping angle of the workpiece flanging, so as to adapt to shaping of the workpiece flanging angles with different intensities. In some embodiments, the adjustment aperture 701 may be an elongated waist aperture.
In some embodiments, the shaping structure may further comprise: the lift pins 702, which are disposed on the second die holder 710 and extend from the pads 725, may be used to remove the shaped workpiece for subsequent handling of the workpiece.
In some embodiments, the second lower die holder 710 may further include a plurality of limiting blocks 703 disposed near 4 corners of the second lower die holder, which may be used to limit the positions of the second lower die holder and the second upper die holder during stamping, so as to control the distance that the shaping block moves toward the pad, and thus the shaping angle of the workpiece flanging. In some embodiments, the height of the limiting block 703 may be adjusted, so as to control the distance that the shaping block moves towards the pad, so as to adjust the shaping angle of the workpiece flanging, and adapt to shaping of the workpiece flanging angles with different intensities.
In some embodiments, the second die holder 710 can also include a side punch structure that has a face that punches a workpiece that is not planar with a face that the punch structure punches a workpiece, the side punch structure including the spacer 704, the drive structure 705, and the punch 706. The positioning liner 704 can position the workpiece and set off to prevent the workpiece from being affected by punching, and the driving structure 705 is similar to the driving in the shaping structure, so that details are not repeated here, and the punch 706 is disposed on the driving structure 705 and punches the workpiece. In some embodiments, the punch 706 may be powder metallurgy die steel, and the heat treatment hardness of the powder metallurgy die steel may be HRC60-66, so that the strength of the punch can be effectively improved, the chipping resistance of the punch is increased, and the ultra-high strength plate can be punched.
In some embodiments, the second progressive die may further include a positioning error obtaining device 708, which may be disposed between the punching structure and the shaping structure and/or between the shaping structure and the side punching structure, may be used to obtain an actual position of the workpiece, and may generate relevant information to the positioning error controller, so that the actual position of the workpiece may be obtained, so as to ensure processing accuracy of the workpiece. In some embodiments, the positioning error acquisition device 708 may be a high definition image acquisition device (e.g., a camera, video camera, etc.) that uses a photograph taken of the workpiece to determine its actual location. In some embodiments, the number of the positioning error obtaining devices may be plural, so that the actual position of the workpiece may be obtained by combining the plural positioning error obtaining devices, which is beneficial to improving the positioning accuracy of the workpiece, ensuring the processing accuracy, and improving the working efficiency. In some embodiments, the positioning error acquisition means may also be a laser sensor.
Fig. 12 is a control flow chart of an ultra-high strength board processing line according to an embodiment of the present invention.
In step 1210, the first stepper controller controls the workpiece to transfer between different stations of the first punch to process the workpiece in different processing steps. In some embodiments, the first stepper controller may receive instructions from the master control station to control the transfer of the workpiece between the different stations. In some embodiments, the first stepper controller may control movement of the workpiece between the blanking, pretreatment, flanging, and transfer zones under the direction of the main console.
In some embodiments, the first error controller controls the first positioning error acquisition device to acquire the actual position of the workpiece and to determine the position error of the workpiece as the workpiece is transferred between different stations of the first punch. In some embodiments, the first error controller notifies the first step controller to adjust the position of the workpiece when the position error of the workpiece is determined to be greater than a preset threshold. In some embodiments, the first error controller may receive a main console instruction to control the first positioning error acquisition device to acquire the actual position of the workpiece.
In some embodiments, the first tool feedback controller receives information from the first pressure sensor when the workpiece reaches the flanging zone and determines whether the workpiece is clamped. In some embodiments, when it is determined that the workpiece is not clamped, the first stepper controller is notified to halt processing and an alarm is sent to request manual intervention. In some embodiments, the alert issued may be a light, sound, or pictogram, etc. In some embodiments, the first tooling feedback controller may receive a main console instruction to receive the first pressure sensor information.
In step 1220, after the work piece is processed in the first punch (also referred to as transferring the work piece to a transfer area), the transport mechanism transfers the work piece to the second punch. In some embodiments, when the workpiece reaches the transfer area, the master control station may send instructions to the transport mechanism that control the transport mechanism to transfer the workpiece to the second punch press. In some embodiments, the transport mechanism may transfer the workpiece to a feed area of the second punch.
In step 1230, the second stepper controller controls the transfer of the workpiece between different stations of the second punch to perform different machining processes on the workpiece after the workpiece reaches the second punch. In some embodiments, the second stepper controller may receive instructions from the master control station to control the transfer of the workpiece between the different stations. In some embodiments, the second stepper controller may control movement of the workpiece between the feed zone, the punch zone, the shaping zone, the side punch zone, and the discharge zone under the direction of the master control station.
In some embodiments, the second error controller controls the second positioning error acquisition device to acquire the actual position of the workpiece and determine the position error of the workpiece when the workpiece is transferred between different stations of the second punch. In some embodiments, the second error controller notifies the second step controller to adjust the position of the workpiece when the position error of the workpiece is determined to be greater than a preset threshold. In some embodiments, the second error controller may receive a command from the main control console to control the second positioning error obtaining device to obtain the actual position of the workpiece.
In some embodiments, the second tool feedback controller receives information from the second pressure sensor and determines whether the workpiece is clamped when the workpiece reaches the shaping zone. In some embodiments, when it is determined that the workpiece is not clamped, the second stepper controller is notified to halt processing and an alarm is sent to request manual intervention. In some embodiments, the alert issued may be a light, sound, or pictogram, etc. In some embodiments, the second tooling feedback controller may receive a main console instruction to receive the second pressure sensor information.
In some embodiments, after the work piece is processed in the second punch (also referred to as transferring the work piece to the outfeed area), the work piece is processed out of the second punch.
The processing production line of the ultra-high strength plate has the characteristics of high specific efficiency, long service life, high qualification rate, low cost, high safety and the like.
1. High efficiency
The cold stamping die in the processing production line can complete the processes of blanking, flanging, bending, deep drawing, three-dimensional forming, assembling and the like of complex parts, reduces the works of intermediate transfer, repeated positioning and the like, does not influence the production efficiency due to the increase of the number of stations, and can stamp very small precise parts. The production efficiency (the continuous die stroke frequency can reach 20-60 stroke frequency/min) can be greatly improved, the material utilization rate is improved by 10-20%, the die can be effectively protected, the labor requirement is reduced, the labor cost is reduced by 15-25%, and the large-scale production can be realized.
2. Long service life
The complex internal shape and the complex external shape of the die in the processing production line can be decomposed into simple male die and female die shapes, the steps can be gradually punched, the working procedures can be dispersed in a plurality of working stations, and the vacancy can be further arranged in the concentrated working procedure area, so that the problem that the wall thickness of the male die and the wall thickness of the female die are too small is avoided, the stress state of the male die and the concave die is changed, and the strength of the die is improved. In addition, the stripper plate of the die can also be used as a guide plate of the male die, which is very beneficial to prolonging the service life of the die, and the service life of the die can reach 100 ten thousand times.
3. High qualification rate
All forming procedures of the product are finished in one pair of dies in the processing production line, so that the operation invariance and accumulated errors caused by multiple positioning during production by using a simple die are overcome, and the quality of the product can be effectively improved.
4. Low cost
The processing production line has high production efficiency, less occupied number of presses, less number of operators and workshop area, and reduced storage and transportation of semi-finished products, thereby having low comprehensive production cost of product parts.
5. Safety of
The operator does not have to extend hands into the dangerous area of the die during stamping in the processing production line. For batch production, an automatic conveying mechanism is also adopted, so that the safety of the die can be greatly improved.
The above embodiments are provided for illustrating the present invention and not for limiting the present invention, and various changes and modifications may be made by one skilled in the relevant art without departing from the scope of the present invention, therefore, all equivalent technical solutions shall fall within the scope of the present disclosure.
Claims (10)
1. A workpiece production line control system, wherein the workpiece production line comprises a first punch press and a second punch press, on which a plurality of different stations are respectively arranged, comprising:
a main control console;
a first subsystem disposed on the first punch press, comprising: a first stepper controller configured to control transfer of the workpiece between different stations in the first punch press, a first positioning error controller configured to obtain a positioning error of the workpiece, and a first tooling feedback controller configured to obtain the workpiece clamping condition;
a first positioning error acquisition device disposed on the first punch and configured to obtain an actual position of the workpiece and communicate to the first positioning error controller;
The first pressure sensor is arranged on the first punch and is in feedback control communication connection with the first tool, and is used for obtaining the clamping condition of the workpiece;
a second subsystem disposed on the second punch press, comprising: a second step controller configured to control transfer of the workpiece between different stations in the second punch press, a second positioning error controller configured to obtain a positioning error of the workpiece, and a second tooling feedback controller configured to obtain the workpiece clamping condition;
a second positioning error acquisition device disposed on the second punch and configured to acquire an actual position of the workpiece and communicate to the second positioning error controller;
the second pressure sensor is arranged on the second punching machine and is in feedback control communication connection with the second tool and is used for obtaining the clamping condition of the workpiece; and
a transport mechanism configured to transport the workpiece between the first punch and the second punch.
2. The workpiece production line control system of claim 1, wherein a first progressive die is provided on the first punch, a second progressive die is provided on the second punch, a plurality of areas are further included on the first progressive die and the second progressive die, and different processing procedures are further included in each area.
3. The workpiece production line control system of claim 2, wherein the machining process includes, but is not limited to: blanking, pretreatment, blanking, flanging, transferring, feeding, punching, shaping, side punching, discharging, bending, deep drawing and three-dimensional pressing.
4. The workpiece production line control system of claim 1, wherein the workpiece production line further comprises: and the third punch is provided with a third progressive die.
5. The workpiece production line control system of claim 1, wherein the first positioning error acquisition device and the second positioning error acquisition device are high definition image acquisition devices or laser sensors.
6. A workpiece production line control method, characterized by comprising:
the first stepping controller receives the instruction of the main control console and controls the workpiece to be transferred and processed between different stations of the first punch;
when the workpiece is transferred between different stations, the first error controller receives the instruction of the main control console, controls the first positioning error acquisition device to acquire the actual position of the workpiece, judges the first positioning error of the workpiece, and receives the instruction of the main control console and the information of the first pressure sensor to judge the first clamping condition of the workpiece;
After the workpiece is processed in the first punch, the conveying mechanism receives the instruction of the main control console and transfers the workpiece to the second punch;
the second stepping controller receives the command of the main control console and controls the workpiece to be transferred and processed between different stations of the second punch; and
when the workpiece is transferred between different stations, the second error controller receives the instruction of the main control console, controls the second positioning error acquisition device to acquire the actual position of the workpiece and judges the second positioning error of the workpiece, and the second tooling feedback controller receives the instruction of the main control console and receives the information of the second pressure sensor to judge the second clamping condition of the workpiece.
7. The control method of claim 6, wherein the first error controller informs the first stepper controller to adjust the position of the workpiece in response to the first positioning error of the workpiece being greater than a preset threshold.
8. The control method of claim 6, wherein the first tool feedback controller notifies a first stepper controller to halt processing and issues an alarm requesting manual intervention in response to a first clamping condition of the workpiece not clamping.
9. The control method of claim 6, wherein the second error controller informs the second stepper controller to adjust the position of the workpiece in response to the second positioning error of the workpiece being greater than a preset threshold.
10. The control method of claim 6, wherein the second tool feedback controller notifies a second stepper controller to halt processing and issues an alarm requesting manual intervention in response to a second clamping condition of the workpiece not clamping.
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| EP2465637A1 (en) * | 2010-12-20 | 2012-06-20 | TRUMPF Werkzeugmaschinen GmbH + Co. KG | Workpiece holder device for fixing a board-shaped workpiece, in particular a metal sheet to a workpiece movement unit of a machine tool |
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