CN117047570A - Intelligent manufacturing system and manufacturing process for flexible automatic brake disc - Google Patents
Intelligent manufacturing system and manufacturing process for flexible automatic brake disc Download PDFInfo
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- CN117047570A CN117047570A CN202311245093.XA CN202311245093A CN117047570A CN 117047570 A CN117047570 A CN 117047570A CN 202311245093 A CN202311245093 A CN 202311245093A CN 117047570 A CN117047570 A CN 117047570A
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 265
- 238000001514 detection method Methods 0.000 claims abstract description 106
- 238000005498 polishing Methods 0.000 claims abstract description 105
- 238000012545 processing Methods 0.000 claims abstract description 84
- 238000000034 method Methods 0.000 claims abstract description 67
- 230000008569 process Effects 0.000 claims abstract description 48
- 238000004806 packaging method and process Methods 0.000 claims abstract description 15
- 238000007689 inspection Methods 0.000 claims description 83
- 238000004140 cleaning Methods 0.000 claims description 71
- 230000007246 mechanism Effects 0.000 claims description 71
- 238000012360 testing method Methods 0.000 claims description 57
- 239000006249 magnetic particle Substances 0.000 claims description 27
- 238000007599 discharging Methods 0.000 claims description 24
- 230000002159 abnormal effect Effects 0.000 claims description 19
- 239000006247 magnetic powder Substances 0.000 claims description 18
- 238000005520 cutting process Methods 0.000 claims description 16
- 238000001035 drying Methods 0.000 claims description 16
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
- B24B1/00—Processes of grinding or polishing; Use of auxiliary equipment in connection with such processes
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
- B24B41/00—Component parts such as frames, beds, carriages, headstocks
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
- B24B41/00—Component parts such as frames, beds, carriages, headstocks
- B24B41/005—Feeding or manipulating devices specially adapted to grinding machines
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
- B24B49/00—Measuring or gauging equipment for controlling the feed movement of the grinding tool or work; Arrangements of indicating or measuring equipment, e.g. for indicating the start of the grinding operation
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B24—GRINDING; POLISHING
- B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
- B24B55/00—Safety devices for grinding or polishing machines; Accessories fitted to grinding or polishing machines for keeping tools or parts of the machine in good working condition
- B24B55/06—Dust extraction equipment on grinding or polishing machines
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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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Abstract
The invention provides an intelligent manufacturing system and manufacturing process of a flexible automatic brake disc, and belongs to the technical field of brake disc manufacturing. The manufacturing system includes a manufacturing line; the blanking unit is connected with the manufacturing production line and is used for receiving unqualified products and products generated by the manufacturing production line; and the production information unit is used for digitally collecting production elements of the manufacturing production line and the blanking unit and controlling the accurate execution of the production processes of the manufacturing production line and the blanking unit. The manufacturing process comprises blank feeding, blank processing, disc polishing, appearance detection, flaw detection, clean code pasting, shaft disc assembling, balance weight removal, blanking and packaging, and has high automation rate and production efficiency. The invention can reliably control and detect the related key technology and technological process of the brake disc production and manufacturing process, and fully automatically record the whole process production information acquisition, and has high system informatization degree and high product whole process quality reliability and safety.
Description
Technical Field
The invention relates to the technical field of brake disc manufacturing, in particular to an intelligent manufacturing system and manufacturing process of a flexible automatic brake disc.
Background
Currently, disc-shaped foundation brake devices are commonly adopted for foundation brake devices for rail transit vehicles in China, particularly for high-speed motor train unit vehicles. The brake disc is used as an important component of the disc-shaped basic brake device, and the friction surface of the brake disc is pressed by the brake pad in the train braking process so as to realize the train braking, thereby ensuring the safe and stable running of the train, and having an important function for ensuring the safe and reliable running of the train. Because the stress condition of the brake disc in the use process is extremely complex, extremely high production and manufacturing requirements are put forward on the dimensional and form and position tolerance precision of each part of the brake disc, the surface quality of the part, the fastening reliability of a fastening piece and the like.
The traditional production process is basically finished by manpower, a large amount of labor force is needed, the labor intensity is high, the problems of high production cost and low efficiency exist, for example, manual recording is adopted for process production data, inspection data, test data and the like in production, the follow-up statistical analysis, anomaly investigation, disposal analysis and the like are caused to be more difficult, meanwhile, the related production plan, order completion condition and equipment condition all need manual offline recording statistics, and the efficiency is quite low. Moreover, with the promotion of product batch, the traditional single-station and discontinuous turnover operation of each process cannot meet the capacity required by modern mass production. In addition, excessive manual participation is unfavorable for quality control of key processes, and the quality of products is easily affected.
Although some automatic processing units in the prior art can realize automatic assembly or inspection of the brake disc, the automatic assembly or inspection of the brake disc cannot be realized, the full-process automation of manufacturing is still not realized, the efficiency and informatization improving effect are limited, the control of the processing quality of parts cannot be realized, and the handling and control capability of the product quality is poor. For example, chinese patent publication No. CN110014292B discloses only a wheel brake disc assembling system and a wheel brake disc assembling process, and the technical scheme is that a middle wheel conveying device is provided to convey the wheel to each station for bolt tightening and detection, and a spray drying device is used to spray the wheel, so that only the operations of manually transferring the wheel and assembling the wheel brake disc are solved, and only the labor intensity of an operator for assembling the wheel brake disc is reduced.
In view of this, there is a need to develop an automated brake disc intelligent manufacturing system that is breakthrough optimized in terms of quality control, efficiency and informatization.
Disclosure of Invention
The invention aims to overcome the defects of the prior art, and provides an intelligent manufacturing system and manufacturing process of a flexible automatic brake disc, which can achieve the purposes of improving the quality control, the production efficiency and the production informatization of the brake disc product.
To achieve the above and other objects, the present invention is achieved by comprising the following technical solutions: as a first aspect, the present invention proposes a flexible automated brake disc intelligent manufacturing system, characterized by a manufacturing line; the blanking unit is connected with the manufacturing production line and is used for receiving unqualified products and products generated by the manufacturing production line; the production information unit comprises a production information acquisition subunit, is communicated with the manufacturing production line and the blanking unit and is used for digitally acquiring production elements of the manufacturing production line and the blanking unit; and the manufacturing execution subunit is communicated with the manufacturing production line, the blanking unit and the production information acquisition subunit and is used for controlling the accurate execution of the production processes of the manufacturing production line and the blanking unit.
In an embodiment, the manufacturing production line comprises a feeding unit, a processing unit, a polishing unit, an appearance and size checking unit, a magnetic powder inspection detecting unit, a cleaning unit, a shaft disc assembling unit and a balance test and weight removing unit which are sequentially arranged along the production and manufacturing process, wherein the feeding unit, the processing unit, the polishing unit, the appearance and size checking unit, the magnetic powder inspection detecting unit, the cleaning unit, the shaft disc assembling unit and the balance test and weight removing unit are connected through a carrying unit.
Further, the polishing unit comprises a disc polishing robot and a disc polishing control system, wherein the disc polishing robot is located near a disc polishing station, the disc polishing control system is embedded in the disc polishing robot, and the disc polishing control system comprises a visual identification module for detecting whether a disc is in place, a polishing execution module for controlling the disc polishing robot, and a polishing feedback module for polishing fault automatic alarming and fault information automatic recording.
In an embodiment, the manufacturing production line comprises a feeding unit, a processing unit, a polishing unit, an appearance and size checking unit, a magnetic particle inspection detecting unit, a cleaning unit and a balance test and weight removing unit which are sequentially arranged along the production and manufacturing process, wherein the feeding unit, the processing unit, the polishing unit, the appearance and size checking unit, the magnetic particle inspection detecting unit, the cleaning unit and the balance test and weight removing unit are connected through a carrying unit.
In one embodiment, the appearance and size inspection unit comprises an appearance and size inspection station and a detection failure blanking level which are sequentially arranged along the detection process, and an inspection measuring mechanism, a three-coordinate measuring machine and a detection recording mechanism which are arranged on the appearance and size inspection station.
In an embodiment, the cleaning unit comprises a cleaning loading level, a cleaning subunit, a rinsing subunit, a wind cutting subunit, a drying subunit, a cleaning unloading level and a pasting subunit arranged in sequence along the cleaning process.
As a second aspect, the invention proposes a flexible automated brake disc intelligent manufacturing process, using the manufacturing system of the first aspect, characterized in that it comprises
Step one, blank feeding: the feeding unit conveys blanks to the processing unit;
step two, blank processing: machining the blank in the machining unit;
step three, polishing a disc body: conveying the qualified processed product to a polishing unit for polishing;
fourth, appearance detection: the polished qualified products are transported to an appearance and size checking unit for appearance detection;
step five, flaw detection: transporting the appearance and size qualified products to a magnetic powder flaw detection unit for flaw detection;
step six, cleaning and sticking: conveying the qualified flaw detection products to a cleaning unit for cleaning, rinsing, air cutting, drying and stacking;
step seven, shaft disc assembly: conveying the clean qualified products to a shaft disc assembling unit for assembling;
step eight, balancing and de-duplication: conveying the assembled qualified products to a balance test and weight removal unit for balance test, weight removal, deburring and marking;
Step nine, blanking and packaging: the final qualified product flows to a qualified product discharging slideway of the discharging unit, and quality inspection personnel carry out finished product final inspection on the finished product; the finished products qualified in final inspection are unloaded and packaged by packaging personnel;
the production information acquisition subunit records the key quality parameters in the first step to the ninth step in real time, monitors the process execution condition and gives an abnormal alarm; and the manufacturing execution subunit controls the accurate execution of the steps one to nine, processes and forms a product record table according to the information collected by the production information collection subunit, and performs abnormal statistical analysis.
As a third aspect, the present invention provides a flexible automated brake disc intelligent manufacturing process, using the manufacturing system of the first aspect, comprising
Step one, blank feeding: the feeding unit conveys blanks to the processing unit;
step two, blank processing: machining the blank in the machining unit;
step three, polishing a disc body: conveying the qualified processed product to a polishing unit for polishing;
fourth, appearance detection: the polished qualified products are transported to an appearance and size checking unit for appearance detection;
step five, flaw detection: transporting the appearance and size qualified products to a magnetic powder flaw detection unit for flaw detection;
Step six, cleaning and sticking: conveying the qualified flaw detection products to a cleaning unit for cleaning, rinsing, air cutting, drying and stacking;
step seven, balancing and de-duplication: conveying the assembled qualified products to a balance test and weight removal unit for balance test, weight removal, deburring and marking;
step eight, blanking and packaging: the final qualified product flows to a qualified product discharging slideway of the discharging unit, and quality inspection personnel carry out finished product final inspection on the finished product; the finished products qualified in final inspection are unloaded and packaged by packaging personnel;
the production information acquisition subunit records the key quality parameters in the first to eighth steps in real time, monitors the process execution condition and gives an abnormal alarm; and the manufacturing execution subunit controls the accurate execution of the first step to the eighth step, processes and forms a product record table according to the information collected by the production information collection subunit, and performs abnormal statistical analysis.
Further, in the manufacturing process according to the second and third aspects, the fourth step includes
S51: the checking and measuring mechanism identifies the model of the disc body or the disc hub on the appearance and size checking station, and the step S52 is carried out after the completion;
s52: calling a corresponding three-coordinate measuring program of the product, and entering step S53 after finishing;
S53: automatically starting a three-coordinate measuring machine to perform automatic three-coordinate detection on the detection item points, and entering step S54 after finishing the detection;
s54: the three-coordinate detection result data is automatically transmitted to a detection recording mechanism, and step S55 is carried out after the completion of the detection;
s55: automatically judging whether the detection result is qualified or not; if the result is qualified, the step S56 is carried out; if not, the step S57 is carried out;
s56: automatically conveying the qualified tray body or tray hub to the magnetic powder flaw detection unit;
s57: alarming prompt by a detection recording mechanism and proceeding to step S58;
s58: and if the inspector confirms that the material is unqualified, manually transferring to detecting the unqualified material discharging position.
Further, in the manufacturing process according to the second and third aspects, the sixth step includes
Sequentially performing S71 cleaning, S72 rinsing, S73 air cutting and S74 drying, and entering a step S75 after finishing;
s75: the tray body or the tray hub flows from the cleaning blanking position to the code pasting subunit, and the step S76 is carried out after a sensor arranged on the code pasting subunit detects that the tray body or the tray hub is arranged on the code pasting station;
s76: the labeling subunit generates a product code according to the product model and sequence number information, and the step S77 is carried out after the completion;
s77: invoking a code pasting mechanism to absorb the product code, confirming the code pasting position and pasting the product code, and entering step S78 after finishing;
S78: automatically identifying whether the product is a shaft disc; if the disk is the shaft disk, the step S79 is performed; if the wheel disc is the wheel disc, the step S710 is performed;
s79: the production line automatically transfers the product flow to the axle disc assembling unit;
s710: the production line automatically transfers the product flow to the balance test and de-duplication unit.
In summary, compared with the prior art, the invention has the beneficial effects that:
1. the production information unit is arranged in the manufacturing system, so that the digital acquisition of production information and the accurate execution control of the production process of the manufacturing production line and the blanking unit can be realized, and the integration of all production procedures such as feeding, processing, polishing, appearance detection, flaw detection, clean code pasting, shaft disc assembly, balance weight removal, blanking packaging and the like is realized, so that the automation rate and the production efficiency are high; the related key technology and the technological process of the production and manufacturing process of the brake disc product can be reliably controlled and detected, so that the quality reliability and the safety of the whole process of the product are improved; the method can fully automatically record related personnel information, processing data, inspection data, key material information, key tightening parameters, flaw detection balance data and the like in the production process, so that the whole process production information acquisition from blank to finished product package is realized, and the informatization degree of the system is high; the real-time monitoring of the process conditions, the production line order completion conditions, the equipment states and the production abnormal states can be realized, and the effective connection with SAP, QMS and MES systems can be realized;
2. According to the invention, the disc polishing robot embedded with the disc polishing control system is arranged in the polishing unit, so that full-automatic control on disc identification, polishing execution, automatic fault alarm, automatic fault information recording and the like can be realized, and the automation rate and the production and manufacturing efficiency of the manufacturing system and the manufacturing process are further improved;
3. according to the invention, the inspection measuring mechanism, the three-coordinate measuring machine and the detection recording mechanism are arranged on the appearance and size checking station of the appearance and size checking unit, so that model identification, automatic size measurement and automatic recording and judgment of detection results of a disc body or a disc hub on the station can be realized, and the automation rate and the production and manufacturing efficiency of the manufacturing system and the manufacturing process are further improved;
4. the cleaning unit is sequentially provided with the cleaning feeding position, the cleaning subunit, the rinsing subunit, the air-cutting subunit, the drying subunit, the cleaning discharging position and the attaching subunit, so that the cleaning, rinsing, air-cutting and drying of qualified products can be sequentially finished, the cleaning effect is obviously better than that of the traditional cleaning unit, and the qualification rate of the qualified products in the subsequent process can be improved;
5. the invention can carry out modularized self-defining design and expansion according to the product model and structure, thereby meeting the production and manufacturing requirements of products with different structures and different specifications; meanwhile, due to the modularized structural design, stability of system performance and convenience in overhauling and maintenance are guaranteed.
Drawings
Fig. 1 is a schematic diagram of a flexible automated brake disc intelligent manufacturing system according to embodiment 1 of the present invention.
Fig. 2 shows a flow chart of the feeding operation of the tray blank of the feeding unit in embodiment 1 of the present invention.
Fig. 3 shows a flow chart of the loading operation of the hub blank of the loading unit in example 1 of the present invention.
Fig. 4 shows a flow chart of the operation of the processing unit in example 1 of the present invention.
Fig. 5 is a schematic diagram showing the main hardware configuration of the polishing unit in embodiment 1 of the present invention.
Fig. 6 shows a flowchart of the disc body polishing operation of the polishing unit in embodiment 1 of the present invention.
Fig. 7 is a flowchart showing the operation of the appearance and size checking unit in embodiment 1 of the present invention.
Fig. 8 is a flowchart showing the operation of the magnetic particle inspection unit in embodiment 1 of the present invention.
Fig. 9 is a main hardware configuration diagram of a cleaning unit in embodiment 1 of the present invention.
Fig. 10 is a flowchart showing the operation of the cleaning unit in embodiment 1 of the present invention.
Fig. 11 is a flowchart showing the operation of the disk assembly unit in embodiment 1 of the present invention.
FIG. 12 is a flow chart showing the operation of the balance test and deduplication unit in embodiment 1 of the present invention.
Fig. 13 is a schematic diagram of a flexible automated brake disc intelligent manufacturing system according to embodiment 2 of the present invention.
Detailed Description
Please refer to fig. 1 to 13. Other advantages and effects of the present invention will become apparent to those skilled in the art from the following disclosure, which describes the embodiments of the present invention with reference to specific examples.
It should be understood that the structures, proportions, sizes, etc. shown in the drawings are for illustration purposes only and should not be construed as limiting the invention to the extent that it can be practiced, since modifications, changes in the proportions, or adjustments of the sizes, which are otherwise, used in the practice of the invention, are included in the spirit and scope of the invention which is otherwise, without departing from the spirit or scope thereof.
In the present invention, for a clearer description, the following description is made: the term "coupled", where the context clearly indicates otherwise, includes both direct and indirect coupling.
Example 1
As shown in fig. 1, the present embodiment provides a flexible automated brake disc intelligent manufacturing system for automatically manufacturing a shaft disc brake disc, wherein solid lines represent real streams and broken lines represent information streams. The manufacturing system comprises a manufacturing production line, a blanking unit 9 and a production information unit 10, wherein the manufacturing production line is a shaft disc manufacturing production line; the blanking unit 9 is connected with the manufacturing production line and is used for receiving unqualified products and final products generated by the manufacturing production line; the production information unit 10 is respectively communicated with the manufacturing production line and the blanking unit 9, and is used for digitally collecting production elements of the manufacturing system and controlling the accurate execution of the production process of the manufacturing system.
The manufacturing production line comprises a feeding unit 1, a processing unit 2, a polishing unit 3, an appearance and size checking unit 4, a magnetic powder flaw detection unit 5, a cleaning unit 6, a shaft disc assembling unit 7 and a balance test and weight removal unit 8 which are sequentially arranged along the production and manufacturing process, wherein the feeding unit 1, the processing unit 2, the polishing unit 3, the appearance and size checking unit 4, the magnetic powder flaw detection unit 5, the cleaning unit 6, the shaft disc assembling unit 7 and the balance test and weight removal unit 8 are connected through a carrying unit; the blanking unit 9 is respectively connected with the processing unit 2, the polishing unit 3, the appearance and size checking unit 4, the magnetic powder inspection and detection unit 5, the axle disc assembling unit 7 and the balance test and de-weight unit 8, and is used for receiving unqualified products generated by the units and finished products generated by the balance test and de-weight unit 8; the production information unit 10 is respectively connected with the feeding unit 1, the processing unit 2, the polishing unit 3, the appearance and size checking unit 4, the magnetic particle inspection unit 5, the cleaning unit 6, the shaft disc assembling unit 7, the balance test and weight removing unit 8 and the blanking unit 9, and is used for digitally collecting production elements such as related persons, machines, materials, methods, rings and the like of each unit and controlling the accurate operation of the whole flow of the production process.
A corresponding flexible automated brake disc intelligent manufacturing process using the manufacturing system of embodiment 1 includes:
step one, blank feeding: carrying blanks to the processing unit 2 through the feeding unit 1;
step two, blank processing: after blank feeding, blank machining is carried out in the machining unit 2;
step three, polishing a disc body: conveying the qualified products to the polishing unit 3 for polishing;
fourth, appearance detection: the polished qualified products are transported to the appearance and size inspection unit 4 for appearance detection;
step five, flaw detection: transporting the appearance and size qualified products to the magnetic particle inspection detection unit 5 for inspection detection;
step six, cleaning and sticking: the qualified flaw detection products are conveyed to the cleaning unit 6 for cleaning, rinsing, air cutting, drying and code pasting;
step seven, balancing and de-duplication: conveying the assembled qualified products to the balance test and de-duplication unit 8 for performing balance test, de-duplication, deburring and marking;
step eight, blanking and packaging: the final qualified product flow is transferred to a qualified product discharging slideway of the discharging unit 9, and quality inspection personnel carry out finished product final inspection on the finished product; the finished products qualified in final inspection are unloaded and packaged by packaging personnel;
The production information acquisition subunit of the production information unit 10 records the key quality parameters in the first to the ninth steps in real time, monitors the process execution condition, and makes an abnormal alarm; the manufacturing execution subunit of the production information unit 10 controls the accurate execution of the steps one to nine, processes and forms a product record table according to the information collected by the production information collection subunit, and performs abnormal statistical analysis.
Specifically, the feeding unit 1 may include a disc body feeding unit and a disc hub feeding unit that are arranged in parallel. The disc body feeding unit and the disc hub feeding unit can respectively realize the feeding of the shaft disc body and the disc hub, and different feeding unit 1 types can be selected according to different shaft disc sizes. The tray feeding unit can comprise a tray feeding execution subunit and a tray feeding control subunit, wherein the tray feeding control subunit is used for controlling the working operation of the tray feeding execution subunit. The hub feeding unit can comprise a hub feeding execution subunit and a hub feeding control subunit, wherein the hub feeding control subunit is used for controlling the working operation of the hub feeding execution subunit.
Please combine fig. 2, when the disc blank of the axle disc is fed, the method mainly comprises the following working procedures:
s11: the control button of the tray body feeding control subunit is manually operated to control the tray body feeding mechanical arm of the tray body feeding execution subunit to take out tray body blanks from the tray body feeding logistics frame, and the tray body blanks are lifted into the tray body lifting mechanism, and the step S12 is carried out after the completion;
s12: the control button of the tray body feeding control subunit is manually operated to control the tray body jacking mechanism to slowly and stably convey the tray body blank to the tray body feeding level, and the step S13 is performed after the completion;
s13: after the tray body feeding detection sensor of the tray body feeding control subunit detects that the tray body feeding position is provided with a tray body blank, transmitting a signal to the tray body feeding industrial personal computer of the tray body feeding control subunit, and detecting and judging whether the tray body blank of the tray body processing feeding position bin of the processing unit 2 is full or not by the tray body feeding industrial personal computer through the tray body feeding detection sensor; if the tray body processing feeding bin is judged to be full, the step S14 is carried out; if the tray body processing feeding bin is judged not to be full, the step S15 is carried out;
S14: the tray body carrying unit controlled by the tray body feeding industrial personal computer does not execute actions and is in a standby state;
s15: the disc body feeding industrial personal computer controls the disc body carrying unit to operate, the forefront disc body blank is carried to the disc body processing feeding position of the processing unit 2 until the disc body processing feeding position bin is full, and the disc body feeding industrial personal computer controls the disc body carrying unit to stop acting, so that the whole disc body feeding process is completed.
Please refer to fig. 3, when the hub blank of the axle disc is fed, the following working procedures are included:
s21: the control button of the hub feeding control subunit is manually operated to control the hub feeding mechanical arm of the hub feeding execution subunit to take out a hub blank from a hub feeding logistics frame, directly hoist the hub blank to a hub feeding level, and enter step S22 after the completion;
s22: after a hub feeding detection sensor of the hub feeding control subunit detects that a hub blank exists on the hub feeding position, transmitting a signal to a hub feeding industrial personal computer of the hub feeding control subunit, and detecting and judging whether a hub processing feeding position bin of the processing unit 2 is full or not by the hub feeding industrial personal computer through the feeding detection sensor; if the hub processing feeding bin is judged to be full, the step S23 is carried out; if the hub processing feeding bin is judged not to be full, the step S24 is carried out;
S23: the hub carrying unit controlled by the hub feeding industrial personal computer does not execute action and is in a standby state;
s24: the hub loading industrial personal computer controls the hub carrying unit to operate, carries the forefront hub blank to the hub processing loading position of the processing unit 2 until the hub processing loading position bin is full, and controls the hub carrying unit to stop acting, so that the whole hub loading process is completed.
In the feeding process of the disc body blank and the disc hub blank of the shaft disc, a control button of a feeding control subunit is operated manually so as to control a feeding execution subunit to finish the feeding operation of the disc body and the disc hub blank; and once the feeding detection sensor of the feeding control subunit detects that a blank is conveyed to the blank feeding level, the manual mode is changed into the automatic mode, the system can automatically control the blank conveying action, and whether the blank is conveyed to the processing feeding level of the processing unit 2 is automatically judged according to the state of the feeding level bin of the processing unit 2.
The processing unit 2 comprises a disc body processing unit and a disc hub processing unit which are arranged in parallel. The disc body processing unit and the disc hub processing unit can respectively process the shaft disc body and the disc hub, and different types of the processing unit 2 can be selected according to different shaft disc sizes. The tray processing unit can comprise a tray processing feeding level, a tray processing center, a tray processing discharging level, a tray weighing mechanism and a tray stacking mechanism which are sequentially arranged along the processing process, and a tray carrying truss for carrying trays among the tray processing feeding level, the tray processing center, the tray processing discharging level, the tray weighing mechanism and the tray stacking mechanism. The hub processing unit may include a hub processing loading level, a hub processing center, a hub processing unloading level, a hub weighing mechanism, and a hub stacking mechanism, and a hub handling truss for handling the disc between the hub processing loading level, the hub processing center, the hub processing unloading level, the hub weighing mechanism, and the hub stacking mechanism, which are sequentially set along the processing course.
Referring to fig. 4, the processing of the disc body/hub blank of the shaft disc includes the following working procedures:
s31: after receiving the feeding signal of the disc/hub feeding unit (namely, the disc/hub feeding unit has placed the disc/hub blank at the disc/hub processing feeding position), the disc/hub handling truss is mobilized to clamp the disc/hub blank from the disc/hub processing feeding position to the disc/hub processing center;
s32: the disc body/hub processing center calls a corresponding program to process the disc body/hub;
s33: clamping the processed disc body/hub from the disc body/hub carrying truss to the disc body/hub processing blanking position;
s34: starting the disc/hub weighing mechanism to weigh the processed disc/hub;
s35: starting the disc body/hub code pasting mechanism to code and paste codes according to the manufacturing serial number of the disc body/hub which is symmetrically weighted; the code may be a two-dimensional code, a bar code, or the like;
s36: and the tray body/hub carrying truss carries the tray body/hub subjected to stacking to a tray body/hub to-be-polished station of the tray body/hub polishing unit.
In step S36, considering that the hub is a machined part, the hub machining unit may directly perform the sharp chamfering process on the hub, so that the coded hub may also directly flow to the appearance and size inspection unit 4; considering that there are many blank surfaces on the disc body, the joint between the blank surfaces and the machined surfaces needs to be polished by a robot alone, and the blank surfaces must be processed by the polishing unit 3 before the blank surfaces can be transferred to the appearance and size checking unit 4.
The polishing unit 3 may include a disc body polishing unit and a hub polishing unit arranged in parallel. Since the arrangement of the hub sharpening unit is not necessary and the apparatus arrangement of the hub sharpening unit is substantially the same as the disc sharpening unit, only the disc sharpening unit will be described in detail below.
As shown in fig. 5, the disc polishing unit 31 may include a disc to-be-polished station 311, a disc polishing station 312, a polishing reject-discharging station, a disc polishing robot 313 located near the disc polishing station 312, and a disc polishing control system embedded in the disc polishing robot 313, which are sequentially disposed along a polishing process. Wherein, the disc polishing control system may include a visual recognition module for detecting whether a disc is in place, a polishing execution module for controlling the disc polishing robot 313, and a polishing feedback module. The polishing feedback module can realize the functions of automatic alarm of polishing faults and automatic recording of fault information, and reminds operators to timely feed back the faults.
Please refer to fig. 6, wherein the polishing process of the disc body includes the following working procedures:
s41: the disc polishing control system detects whether a disc exists in the disc polishing station; if the disc body polishing station does not have a disc body, the step S42 is carried out; if the disc body exists in the disc body polishing station, the step S43 is carried out;
S42: transferring the disc body on the disc body station to be polished to a disc body polishing station, and entering step S43 after finishing; the method comprises the steps of carrying out a first treatment on the surface of the
S43: controlling the disc body polishing robot to polish the part to be polished according to the product type and the set polishing program, and entering step S44 after finishing the polishing;
s44: the polished tray body without abnormal report feedback is automatically carried to the appearance and size inspection unit 4.
In addition, when abnormal feedback exists in the polishing process, the polishing feedback device carries out unit alarm prompt, and the result is confirmed and treated manually; and if the grinding abnormality is confirmed, manually circulating to a grinding disqualified blanking position.
As the tray body is a forging or casting blank, after the tray body is processed by the processing unit 2, more than 120 processing surface burrs such as irregular corners and the like need to be polished. Traditional solution mainly relies on manual polishing, and the stability of polishing is poor, and the security risk of polishing process is high, and the dust is big to the occupational health harm of operating personnel and is the important problem that puzzles technical staff. The design that this scheme was polished through the motion polishing robot can effectively solve above-mentioned problem. The floating polishing head can be used by the disc polishing robot to stabilize the operation of the disc polishing unit and ensure the polishing effect; the double-station design of the station to be polished and the station to be polished can realize the continuity of the production process.
The appearance and size checking unit 4 is used for checking the appearance and size of the disc body and the disc hub polished by the polishing unit 3 or the disc hub processed by the processing unit 2, and may include an appearance and size checking station and a defective blanking level sequentially set along a detection process, and a checking and measuring mechanism, a three-coordinate measuring machine and a detection and recording mechanism set on the appearance and size checking station.
Referring to fig. 7, the working procedure of the appearance and size checking unit 4 is as follows:
s51: the checking and measuring mechanism identifies the model of the disc body or the disc hub on the appearance and size checking station, and the step S52 is carried out after the completion;
s52: calling a corresponding three-coordinate measuring program of the product, and entering step S53 after finishing;
s53: automatically starting a three-coordinate measuring machine to perform automatic three-coordinate detection on the detection item points, and entering step S54 after finishing the detection;
s54: the three-coordinate detection result data is automatically transmitted to a detection recording mechanism, and step S55 is carried out after the completion of the detection;
s55: automatically judging whether the detection result is qualified or not; if the result is qualified, the step S56 is carried out; if not, the step S57 is carried out;
s56: automatically conveying the qualified tray body or tray hub to the magnetic powder flaw detection unit 5;
S57: alarming prompt by a detection recording mechanism and proceeding to step S58;
s58: and if the inspector confirms that the material is unqualified, manually transferring to detecting the unqualified material discharging position.
The magnetic particle inspection and detection unit 5 can comprise manual code scanning equipment, a magnetic particle inspection auxiliary detection mechanism, magnetic particle inspection equipment, a magnetic particle inspection and detection mechanism, a magnetic particle inspection unqualified blanking level and the like which are sequentially arranged along the inspection process.
Referring to fig. 8, the working procedure of the magnetic particle inspection unit 5 is as follows:
s61: an operator holds a manual code scanning device to scan the code sticking on the tray body or the tray hub, the product number information is recorded, and the step S62 is carried out after the completion;
s62: the operator uncovers the sticking code to facilitate the observation of the magnetic powder inspection process, and the step S63 is carried out after the completion;
s63: controlling the magnetic particle inspection equipment to perform the inspection of the disc body or the disc hub by the magnetic particle inspection detection mechanism, rotating the disc body or the disc hub by the magnetic particle inspection auxiliary detection mechanism so as to facilitate the observation, and entering step S64 after the inspection is completed;
s64: the related detection result of the magnetic powder inspection is input into the magnetic powder inspection detection mechanism by an operator, and the step S65 is carried out after the completion;
s65: automatically judging whether the detection result is qualified or not; if the result is qualified, the step S66 is entered; if not, the step S67 is carried out;
S66: the disk body or the disk hub is withdrawn from the magnetic particle inspection equipment by utilizing the magnetic particle inspection auxiliary detection mechanism and is automatically conveyed to the cleaning unit;
s67: and (3) withdrawing the disc body or the disc hub from the magnetic particle inspection equipment by utilizing the magnetic particle inspection auxiliary detection mechanism, and automatically carrying to a position where the magnetic particle inspection is unqualified.
As shown in fig. 9, the cleaning unit 6 may include a cleaning loading level 61, a cleaning sub-unit 62, a rinsing sub-unit 63, a wind cutting sub-unit 64, a drying sub-unit 65, and a cleaning unloading level 66, which are sequentially disposed along the cleaning process. Each subunit is a pass-through unit, namely, the disc body or the disc hub can integrally pass through each subunit, and the functions of each subunit are synchronously realized.
Wherein the cleaning flow rate and the passing time of the cleaning subunit 62 are adjustable; the rinsing flow and the passing time of the rinsing subunit 63 are adjustable; the wind cutting flow and the passing time of the wind cutting subunit 64 are adjustable; the drying temperature and the flow rate of the hot air and the passing time of the drying subunit 65 are adjustable; so that each subunit can adjust the cleaning flow and the passing time according to the model of the product and the like.
Referring to fig. 10, after the subunits of the cleaning unit 6 adjust parameters according to the product model, the tray body or the tray hub sequentially performs S71 cleaning, S72 rinsing, S73 air cutting, S74 drying through the subunits, and then cleaning is completed, and step S75 is performed;
S75: the tray body or the tray hub flows from the cleaning discharging position 66 to a code pasting subunit, and the step S76 is carried out after a sensor arranged on the code pasting subunit detects that the tray body or the tray hub is arranged on the code pasting station; the code pasting unit comprises a code pasting station and a code pasting mechanism positioned on the code pasting station;
s76: the labeling subunit generates a product code according to the model and sequence number information of the disk body or the disk hub, and the step S77 is carried out after the completion;
s77: invoking a code pasting mechanism to absorb the product code, confirming the code pasting position and pasting the product code, and entering step S78 after finishing;
s78: automatically identifying whether the disc body or the disc hub belongs to the shaft disc; if the shaft disk belongs to the shaft disk, the step S79 is performed; if the wheel belongs to the wheel disc, the step S710 is performed;
s79: the production line automatically transfers the disk body and the disk hub belonging to the shaft disk assembling unit 7;
s710: the production line automatically transfers the disk body belonging to the wheel disk to the balance test and weight removing unit 8.
It should be noted that, steps S78, S79 and S710 are the setting of the flexible automatic brake disc intelligent manufacturing system when the production and the manufacturing of the axle disc and the wheel disc can be simultaneously performed, and when only the production and the manufacturing of the axle disc are performed, the product after completing step S77 will all be directly circulated to the axle disc assembling unit 7.
The axle disc assembling unit 7 may include a fitting feeding and distributing mechanism, a disc hub aligning mechanism, a disc body aligning mechanism, a brake disc assembling mechanism, a bolt fastening mechanism, an axle disc assembly disqualification blanking level, and the like, which are sequentially arranged along the assembling process.
Referring to fig. 11, the workflow of the axle disc assembling unit 7 is as follows:
s81: after the assembled disc body, the disc hub and the fittings are inspected to be qualified, the disc body, the disc hub and the fittings are conveyed to the corresponding positions of the shaft disc assembling unit 7 through the fitting feeding and distributing mechanism;
s82: the disc hub alignment mechanism is used for aligning and fixing the disc hub;
s83: the disc body alignment mechanism aligns and fixes the disc body and is positioned and assembled with the disc hub according to the design requirement;
s84: the brake disc assembling mechanism sequentially completes the assembly of accessories such as bolts, gaskets, nuts and the like;
s85: the bolt fastening mechanism completes the positioning of the fastener, the matching of the tightening equipment and the fastener, and the automatic tightening of the bolt;
s86: after the screwing is finished, the bolt fastening mechanism is withdrawn from the fastener;
s87: the assembled reel automatically flows to the balancing test and de-duplication unit 8.
When the automatic assembling process of the fastening piece is carried out by calling the bolt fastening mechanism, if abnormal fastening torque, axial force or appearance of the fastening piece occurs in the fastening process, the bolt fastening mechanism can carry out unit alarm prompt, and the assembling process, the result and the like are confirmed and treated manually; and if the assembly is abnormal, manually transferring to a blanking position with unqualified shaft disc assembly.
The balance test and de-duplication unit 8 comprises a balance test mechanism and a de-duplication marking mechanism. The balance test mechanism can be used for a balance test of a shaft-mounted brake disc or a wheel disc body. The weight removing and marking mechanism can realize the operations of removing weight, removing burrs, marking and the like of the shaft-mounted brake disc or the wheel disc body. The axle-mounted brake disc assembled by the axle disc assembling unit 7 is transported to the balance test mechanism by a transporting unit; after the workpiece is placed, the carrying truss moves to a safe position.
Referring to fig. 12, the working procedure of the balancing test and deduplication unit 8 is as follows:
s91: after the qualified products are assembled in place, the balance test mechanism is started to perform a balance test, and step S92 is performed after the balance test is completed;
s92: automatically judging whether the residual unbalance value meets the technical requirement according to the balance test result, and if the residual unbalance value meets the technical requirement, entering step S93; if the residual unbalance does not meet the technical requirement, the step S94 is entered;
s93: starting the duplication eliminating and marking mechanism to automatically mark the product, and carrying the product to a qualified product discharging slideway after finishing;
s94: starting the duplication eliminating and marking mechanism to duplication eliminating the product, and entering step S95 after the duplication eliminating and marking mechanism is completed;
S95: starting the balance test mechanism to carry out balance test retest, and entering step S96 after finishing the balance test;
s96: automatically judging whether the residual unbalance value meets the technical requirement according to the retest result of the balance test, and if the residual unbalance value meets the technical requirement, entering step S97; if the residual unbalance does not meet the technical requirements, the step S98 is carried out;
s97: starting the duplication removing and marking mechanism to remove burrs of the product, and entering step S93 after finishing;
s98: starting the duplication removal marking mechanism to carry out secondary duplication removal on the product, and entering step S99 after the duplication removal marking mechanism is completed;
s99: starting the balance test mechanism to perform balance test secondary retest, and entering step S910 after finishing the balance test;
s910: automatically judging whether the residual unbalance value meets the technical requirement according to the retest result of the balance test, and if the residual unbalance value meets the technical requirement, entering step S97; if the residual unbalance does not meet the technical requirement, step S911 is performed;
s911: scrapping, namely automatically carrying the product to a balance waste product discharging slideway.
The blanking unit 9 comprises a processing waste blanking slideway, a polishing waste blanking slideway, an appearance waste blanking slideway, a dimension waste blanking slideway, a flaw detection waste blanking slideway, an assembly waste blanking slideway, a balance waste blanking slideway, a qualified product blanking slideway, a blanking turnover mechanism, a blanking control cabinet and the like;
The processing waste product blanking slide way, the polishing waste product blanking slide way, the appearance and size waste product blanking slide way, the flaw detection waste product blanking slide way, the assembly waste product blanking slide way and the balance waste product blanking slide way are respectively connected with corresponding processing unit 2, polishing unit 3, appearance and size inspection unit 4, magnetic powder flaw detection unit 5, shaft disc assembly unit 7 and tail end disqualification blanking stations of balance test and weight removal unit 8, and after disqualification is confirmed by manpower, the tail end disqualification blanking stations are directly circulated to the corresponding scrapped product blanking slide way. Since the loading unit 1 and the cleaning unit 6 generally do not generate scrap, the arrangement of a blank scrap discharging chute and a cleaning scrap discharging chute is not necessary.
For products which are judged to be qualified through the balance test and weight removal unit 8 and are transferred to a qualified product blanking slideway, a quality inspector operates a blanking control cabinet to control a blanking turnover mechanism to act, so that final finished products such as appearance, identification and the like are inspected; and operating a blanking control cabinet by a packer to discharge the finished product from the blanking unit 9 and finish packaging.
The production information unit 10 includes a production information acquisition sub-unit and a manufacturing execution sub-unit.
The production information acquisition subunit can digitally acquire production elements such as related people, machines, materials, methods, rings and the like of each production procedure, and complete the whole process production of products from blanks to finished product packages and the whole process production information acquisition. Specifically, in the working personnel of the working procedures of the processing unit 2, the appearance and size checking unit 4, the magnetic powder inspection and detection unit 5, the shaft disc assembling unit 7, the balance test and duplication removal unit 8 and the like, the skills, names and work cards of the personnel are bound through a personnel management module, the cards are swiped and registered before the working, and the judgment and the recording are automatically carried out by the units; the key data of the equipment are recorded through grabbing PLC data on machining equipment, polishing robot equipment, flaw detection equipment, cleaning equipment, tightening equipment, balance equipment and the like; the axle disc assembling unit 7 performs code scanning, inputting and collecting on information such as a production process disc body casting number, a disc hub number, a space ring number, a fastener batch number and the like.
The manufacturing execution subunit collects production process information by using laser, displacement, force sensor and image sensing equipment, and completes association of product information by automatic code pasting and automatic code scanning equipment in a manufacturing production line, so as to process and form a product record table, abnormal statistical analysis and the like. The manufacturing execution subunit realizes real-time monitoring of each working procedure of the product in the manufacturing condition, the order completion condition of the production line, the equipment state and the abnormal production state, and dynamic monitoring and visualization of personnel information, inspection data, key material information, flaw detection balance data, equipment state, key tightening parameters, test parameters and other whole-flow and whole-element data in the production process, strengthens the quality control of the production process and improves the management level.
Example 2
As shown in FIG. 13, the invention also provides another flexible automated brake disc intelligent manufacturing system for automated production of wheel disc brake discs, wherein solid lines represent real flow and broken lines represent information flow. The manufacturing system comprises a wheel disc manufacturing production line, a blanking unit 9 and a production information unit 10, wherein the blanking unit 9 is connected with the wheel disc manufacturing production line and is used for receiving unqualified products and final products generated by the wheel disc manufacturing production line; the production information unit 10 is respectively connected with the wheel disc manufacturing production line and the blanking unit 9, and is used for digitally collecting production elements of the manufacturing system and controlling the accurate execution of the production process of the manufacturing system.
The wheel disc manufacturing production line comprises a feeding unit 1, a processing unit 2, a polishing unit 3, an appearance and size checking unit 4, a magnetic particle inspection detecting unit 5, a cleaning unit 6 and a balance test and weight removing unit 8 which are sequentially arranged along the manufacturing process, wherein the feeding unit 1, the processing unit 2, the polishing unit 3, the appearance and size checking unit 4, the magnetic particle inspection detecting unit 5, the cleaning unit 6 and the balance test and weight removing unit 8 are connected through a carrying unit; the blanking unit 9 is respectively connected with the processing unit 2, the polishing unit 3, the appearance and size checking unit 4, the magnetic powder inspection and detection unit 5 and the balance test and weight removal unit 8 and is used for receiving unqualified products and final qualified products generated in each production procedure; the production information unit 10 is respectively connected with the feeding unit 1, the processing unit 2, the polishing unit 3, the appearance and size checking unit 4, the magnetic particle inspection and detection unit 5, the cleaning unit 6, the balance test and weight removal unit 8 and the blanking unit 9, and is used for digitally collecting production elements such as related persons, machines, materials, methods, rings and the like of each production procedure and controlling the whole flow of the production process.
The manufacturing system for manufacturing the wheel disc type brake disc by automatic production is different from the manufacturing system for manufacturing the axle disc type brake disc by automatic production only in that the wheel disc type brake disc only comprises a wheel disc body and no disc hub, so that operations such as feeding, machining and polishing of the disc hub are not required, and assembly of the disc body and the disc hub is not required, and hardware equipment and software control programs required by the production of the disc hub can be omitted.
A corresponding flexible automated brake disc intelligent manufacturing process using the manufacturing system of example 2 includes:
step one, blank feeding: carrying blanks to the processing unit 2 through the feeding unit 1;
step two, blank processing: after blank feeding, blank machining is carried out in the machining unit 2;
step three, polishing a disc body: conveying the qualified products to the polishing unit 3 for polishing;
fourth, appearance detection: the polished qualified products are transported to the appearance and size inspection unit 4 for appearance detection;
step five, flaw detection: transporting the appearance and size qualified products to the magnetic particle inspection detection unit 5 for inspection detection;
step six, cleaning and sticking: the qualified flaw detection products are conveyed to the cleaning unit 6 for cleaning, rinsing, air cutting, drying and code pasting;
Step seven, balancing and de-duplication: conveying the assembled qualified products to the balance test and de-duplication unit 8 for performing balance test, de-duplication, deburring and marking;
step eight, blanking and packaging: the final qualified product flow is transferred to a qualified product discharging slideway of the discharging unit 9, and quality inspection personnel carry out finished product final inspection on the finished product; the finished products qualified in final inspection are unloaded and packaged by packaging personnel;
the production information acquisition subunit of the production information unit 10 records the key quality parameters in the first to eighth steps in real time, monitors the process execution condition, and gives an abnormal alarm; the manufacturing execution subunit of the production information unit 10 controls the accurate execution of the steps one to eight, processes and forms a product record table according to the information collected by the production information collection subunit, and performs abnormal statistical analysis.
Example 3
The axle disc/wheel disc manufacturing production line of the flexible automatic brake disc intelligent manufacturing system is different from the axle disc/wheel disc manufacturing production line of the flexible automatic brake disc intelligent manufacturing system in the embodiment 1 and the embodiment 2, namely, a multi-unit design, namely, a multi-equipment, multi-station and multi-station design; the axle dish/rim plate manufacturing production line of flexible automatic brake disc intelligent manufacturing system that this embodiment provided adopts single processing equipment design, accomplishes blank material loading, blank processing, disk body polishing, outward appearance detection, inspection detection, clean sign indicating number, balanced multiple operation that removes weight and unloading were packed in proper order on single station through single processing equipment's automatic positioning mechanism and clamping mechanism to thereby can realize the processing of different models, structure products according to product structure automated programming.
Therefore, the invention effectively overcomes various defects in the prior art and has high industrial utilization value. The above embodiments are merely illustrative of the principles of the present invention and its effectiveness, and are not intended to limit the invention. Modifications and variations may be made to the above-described embodiments by those skilled in the art without departing from the spirit and scope of the invention. Accordingly, it is intended that all equivalent modifications and variations of the invention be covered by the claims, which are within the ordinary skill of the art, be within the spirit and scope of the present disclosure.
Claims (10)
1. An intelligent manufacturing system for a flexible automated brake disc, comprising
A manufacturing production line;
the blanking unit is connected with the manufacturing production line and is used for receiving unqualified products and products generated by the manufacturing production line; producing an information unit comprising
The production information acquisition subunit is communicated with the manufacturing production line and the blanking unit and is used for digitally acquiring production elements of the manufacturing production line and the blanking unit;
and the manufacturing execution subunit is communicated with the manufacturing production line, the blanking unit and the production information acquisition subunit and is used for controlling the accurate execution of the production processes of the manufacturing production line and the blanking unit.
2. The manufacturing system according to claim 1, wherein the manufacturing line includes a feeding unit, a processing unit, a polishing unit, an appearance and size inspection unit, a magnetic particle inspection unit, a cleaning unit, a shaft disc assembling unit, and a balance test and weight removal unit, which are sequentially disposed along the manufacturing process, and the feeding unit, the processing unit, the polishing unit, the appearance and size inspection unit, the magnetic particle inspection unit, the cleaning unit, the shaft disc assembling unit, and the balance test and weight removal unit are connected by a handling unit.
3. The manufacturing system of claim 2, wherein the polishing unit comprises a disc polishing robot located near a disc polishing station and a disc polishing control system embedded in the disc polishing robot, the disc polishing control system comprising a visual identification module for detecting whether a disc is in place, a polishing execution module for controlling the disc polishing robot, and a polishing feedback module for polishing failure automatic alarm and failure information automatic recording.
4. The manufacturing system according to claim 1, wherein the manufacturing line comprises a feeding unit, a processing unit, a polishing unit, an appearance and size inspection unit, a magnetic particle inspection unit, a cleaning unit, and a balance test and de-duplication unit, which are sequentially arranged along the manufacturing process, and the feeding unit, the processing unit, the polishing unit, the appearance and size inspection unit, the magnetic particle inspection unit, the cleaning unit, and the balance test and de-duplication unit are connected by a handling unit.
5. The manufacturing system according to claim 2 or 4, wherein the appearance and size inspection unit includes an appearance and size inspection station and a detection reject level disposed in this order along the inspection process, and an inspection measuring mechanism, a three-coordinate measuring machine, and a detection recording mechanism disposed on the appearance and size inspection station.
6. The manufacturing system of claim 2 or 4, wherein the cleaning unit comprises a cleaning loading level, a cleaning subunit, a rinsing subunit, a wind cutting subunit, a drying subunit, a cleaning unloading level, and a pasting subunit, which are sequentially arranged along the cleaning process.
7. A flexible automated brake disc intelligent manufacturing process using a manufacturing system as claimed in any one of claims 1-3 and 5-6, comprising
Step one, blank feeding: the feeding unit conveys blanks to the processing unit;
step two, blank processing: machining the blank in the machining unit;
step three, polishing a disc body: conveying the qualified processed product to a polishing unit for polishing;
fourth, appearance detection: the polished qualified products are transported to an appearance and size checking unit for appearance detection;
step five, flaw detection: transporting the appearance and size qualified products to a magnetic powder flaw detection unit for flaw detection;
Step six, cleaning and sticking: conveying the qualified flaw detection products to a cleaning unit for cleaning, rinsing, air cutting, drying and stacking;
step seven, shaft disc assembly: conveying the clean qualified products to a shaft disc assembling unit for assembling;
step eight, balancing and de-duplication: conveying the assembled qualified products to a balance test and weight removal unit for balance test, weight removal, deburring and marking;
step nine, blanking and packaging: the final qualified product flows to a qualified product discharging slideway of the discharging unit, and quality inspection personnel carry out finished product final inspection on the finished product; the finished products qualified in final inspection are unloaded and packaged by packaging personnel;
the production information acquisition subunit records the key quality parameters in the first step to the ninth step in real time, monitors the process execution condition and gives an abnormal alarm; and the manufacturing execution subunit controls the accurate execution of the steps one to nine, processes and forms a product record table according to the information collected by the production information collection subunit, and performs abnormal statistical analysis.
8. A flexible automated brake disc intelligent manufacturing process using a manufacturing system as claimed in any one of claims 1 or 4-6, comprising
Step one, blank feeding: the feeding unit conveys blanks to the processing unit;
Step two, blank processing: machining the blank in the machining unit;
step three, polishing a disc body: conveying the qualified processed product to a polishing unit for polishing;
fourth, appearance detection: the polished qualified products are transported to an appearance and size checking unit for appearance detection;
step five, flaw detection: transporting the appearance and size qualified products to a magnetic powder flaw detection unit for flaw detection;
step six, cleaning and sticking: conveying the qualified flaw detection products to a cleaning unit for cleaning, rinsing, air cutting, drying and stacking;
step seven, balancing and de-duplication: conveying the assembled qualified products to a balance test and weight removal unit for balance test, weight removal, deburring and marking;
step eight, blanking and packaging: the final qualified product flows to a qualified product discharging slideway of the discharging unit, and quality inspection personnel carry out finished product final inspection on the finished product; the finished products qualified in final inspection are unloaded and packaged by packaging personnel;
the production information acquisition subunit records the key quality parameters in the first to eighth steps in real time, monitors the process execution condition and gives an abnormal alarm; and the manufacturing execution subunit controls the accurate execution of the first step to the eighth step, processes and forms a product record table according to the information collected by the production information collection subunit, and performs abnormal statistical analysis.
9. The manufacturing process according to claim 7 or 8, wherein the fourth step comprises
S51: the checking and measuring mechanism identifies the model of the disc body or the disc hub on the appearance and size checking station, and the step S52 is carried out after the completion;
s52: calling a corresponding three-coordinate measuring program of the product, and entering step S53 after finishing;
s53: automatically starting a three-coordinate measuring machine to perform automatic three-coordinate detection on the detection item points, and entering step S54 after finishing the detection;
s54: the three-coordinate detection result data is automatically transmitted to a detection recording mechanism, and step S55 is carried out after the completion of the detection;
s55: automatically judging whether the detection result is qualified or not; if the result is qualified, the step S56 is carried out; if not, the step S57 is carried out;
s56: automatically conveying the qualified tray body or tray hub to the magnetic powder flaw detection unit;
s57: alarming prompt by a detection recording mechanism and proceeding to step S58;
s58: and if the inspector confirms that the material is unqualified, manually transferring to detecting the unqualified material discharging position.
10. The manufacturing process according to claim 7 or 8, wherein the sixth step comprises
Sequentially performing S71 cleaning, S72 rinsing, S73 air cutting and S74 drying, and entering a step S75 after finishing;
s75: the tray body or the tray hub flows from the cleaning blanking position to the code pasting subunit, and the step S76 is carried out after a sensor arranged on the code pasting subunit detects that the tray body or the tray hub is arranged on the code pasting station;
S76: the labeling subunit generates a product code according to the model and sequence number information of the disk body or the disk hub, and the step S77 is carried out after the completion;
s77: invoking a code pasting mechanism to absorb the product code, confirming the code pasting position and pasting the product code, and entering step S78 after finishing;
s78: automatically identifying whether the production disc body or the disc hub belongs to the shaft disc; if the shaft disk belongs to the shaft disk, the step S79 is performed; if the wheel belongs to the wheel disc, the step S710 is performed;
s79: the production line automatically flows the disk body and the disk hub belonging to the shaft disk assembling unit;
s710: the production line automatically transfers the disk body belonging to the wheel disk to the balance test and weight removing unit.
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| CN202311245093.XA CN117047570A (en) | 2023-09-25 | 2023-09-25 | Intelligent manufacturing system and manufacturing process for flexible automatic brake disc |
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| CN202311245093.XA CN117047570A (en) | 2023-09-25 | 2023-09-25 | Intelligent manufacturing system and manufacturing process for flexible automatic brake disc |
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Address after: No. 19 Shunyuan Road, Xinbei District, Changzhou City, Jiangsu Province, 213000 Applicant after: CRRC CHANGZHOU TECH-MARK INDUSTRIAL Co.,Ltd. Applicant after: CRRC Qishuyan Locomotive and Rolling Stock Technology Research Institute Co.,Ltd. Address before: No. 19 Shunyuan Road, Xinbei District, Changzhou City, Jiangsu Province, 213000 Applicant before: CRRC CHANGZHOU TECH-MARK INDUSTRIAL Co.,Ltd. Applicant before: CRRC QISHUYAN INSTITUTE Co.,Ltd. |
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| CB02 | Change of applicant information |