Scheme design of the hottest automatic unmanned fa

2022-10-23
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This paper introduces the scheme of an automatic unmanned processing factory designed by Juneng robot for a water pump manufacturer. The automatic chemical plant is composed of three lines: the production line of water pump end cover components, the production line of inner and outer bearing components and the production line of water pump base. It is designed according to the specifications of the plant with a span of 30 meters. A 4-meter-wide channel is reserved at the head and both sides of the plant. The middle is the main body of the production line. The production line is 22 meters wide and 63 meters long. A centralized workpiece collection and detection area is set at one end of the production line, Inspect the processed parts and manage the transfer of parts. As a verification of the scheme, Juneng robot has trial produced a production line of water pump end cover (as shown in Figure 1), which has fully met the design requirements after actual processing verification

Figure 1 one corner of the water pump end cover production line

the production line is in full-automatic operation mode. The field bus CC-Link technology is used to control and monitor the equipment on the line in real time, and a general control room is set to control the production status of the whole line. A large screen is set on the production line to display the status information of the production line in real time. Fieldbus CC-Link (the goal of control & Communication Lin service and in a word, it is becoming more and more clear in customer service practice) technology integrates the fieldbus technology of control and information processing. It is a kind of provincial wiring and information network. It not only has the functions of high real-time, decentralized control, communication with intelligent devices, RAS and so on, but also relies on close contact with many field device manufacturers to provide an open environment. Because CC link can directly connect various field devices such as flow meters, solenoid valves, temperature controllers, etc., it reduces the wiring cost and facilitates the change of wiring design; Through the repeater, the high-speed communication speed of 10m can be maintained within 4.3 kilometers. CC link has outstanding advantages such as excellent performance, wide application, simple use, cost saving and so on. It not only solves the complex problem of industrial field wiring, but also has excellent anti noise performance and compatibility. CC link is a network mainly based on the device layer, which can also cover the higher-level control layer and the lower level sensor layer. In July, 2005, CC link was approved by China National Standards Committee as the guiding technical document of China national standards

the general control room of the automatic chemical plant can not only monitor and manage the status of the production line, but also connect to the air conditioning, air pressure, power and other auxiliary systems of the plant through fieldbus technology, so as to realize the real monitoring and management of the operation of the whole plant

process scheme design

the production program of the automatic production plant is to produce 200000 pieces per year, and the production pace is a set of kits in 1 minute. There are three same branches in the pump end cap assembly production line. If one of them fails, the other two can continue to work, and the whole production line will not stop. The same design is also used in the production line of the water pump base, and two branch lines with the same configuration are also used

1. Water pump end cover assembly production line

the composition of water pump end cover assembly production line includes water pump end cover branch line, pressure ring branch line, component branch line, centralized pallet chute, sampling inspection station, press fitting station, marking station, workpiece output chute, workpiece detection area, leakage testing area, packaging area, etc

1.1 the process of the branch line of the end cover of the water pump

the layout of the line is composed according to the sequence of the end cover, pressure ring and components of the water pump, as shown in Figure 2. The beat of one line of pump end cover parts is 3 minutes, and the average beat of the three lines is 1 minute, meeting the requirement of annual output of 200000 pieces. Each branch line is equipped with a 20 position silo, which can fill 100 parts at a time. According to the beat of 3 minutes, a single filling can work continuously for 5 hours

Figure 2 overall process layout of the fully automatic scheme

the blank of the end cover of the water pump is grabbed by (2) the manipulator of the gantry robot from (1) the automatic silo, and fast forward to the workpiece waiting area of the lathe Op10 in the first process. When the Op10 lathe completes the processing of Op10 in the first process, the manipulator enters the lathe, points to the workpiece exchange area, and first unload the processed parts, After turning the head of the manipulator by 90 °, send the workpiece to the chuck of the lathe, then exit the lathe and fast forward to (5) turnover station, which completes the 180 ° turnover of the parts. The robot grabs the overturned parts and fast forward to the workpiece waiting area of the lathe OP20 in the second process. When the lathe completes the processing of the second process OP20 of the parts, execute the same action as the first process to exchange the parts, Then the robot places the parts completed in the second process on the (6) conveying tray, which is equipped with a positioning device to center the parts. The conveying tray transports the parts to the feeding position of the machining center (9). It is reported that when the feeding is needed, it is grabbed by (8) gantry robot, fast forward to (7) angular positioning station to complete the angular positioning of the parts, and then grabbed by the manipulator and sent to the workpiece waiting area of the machining center. The machining center process completes the processing of op30, the third process has three stations, and all three stations are processed after one-time clamping, When feeding is required, first move to the first station of op30 and exchange the processed parts, then put them into the turnover station for 180 ° turnover, then exchange the overturned parts with the parts of the second station, and so on. Exchange the parts with the other two stations in turn, and finally put all the processed parts into the (10) workpiece cleaning station for cleaning, and then put them on the (31) centralized conveying tray, So far, all processes of the pump end cover parts have been completed

Figure 3

1.2 technological process of pressure ring branch line

the production pace of pressure ring branch line is 1 minute, equipped with a 6-station silo, which can fill 300 parts at a time, and a single filling can work continuously for 5 hours. The processing of the pressing ring is also divided into two processes, using robots for loading and unloading. At the same time, in the first process of cutting, we use the tailstock as an auxiliary mechanism, that is, we use the tailstock to support the part to be cut before cutting. The pressing ring uses five parts to share a blank. After five parts are processed continuously by the first order lathe, the robot will load them and continue the next cycle of processing. When the first process Op10 of a pressing ring is processed by the first process Op10 of the first process lathe Op10, (22) the tailstock air claw moves to the workpiece processing area, the inner support blocks the pressing ring parts, rotates with the spindle, the machine tool cuts off the processing, and then the tailstock air claw moves away, (23) the robot of the gantry robot rotates 180 ° horizontally, enters the lathe, exchanges the workpiece with the tailstock air claw, and then exits the spring * mass assembly; The other is the average load hydraulic cylinder machine tool that applies force to the test piece. The lathe Op10 starts to process the next part. At the same time, the robot quickly advances to the processing area of the second sequence lathe OP20, rotating 180 ° horizontally and 90 ° vertically. When the second sequence lathe processing is completed, the robot enters the lathe for workpiece exchange, and then enters the cleaning station of (26) parts to clean the parts, Then put it on the pallet with the pump end cover parts and the positioning fixture of the press mounting station on the (31) centralized conveying pallet, and then the robot returns to the starting waiting position. The pallet and the positioning fixture move to the press mounting station together for press mounting, and the sensor of the press mounting station measures. The unqualified parts are put into the collection box, and the qualified parts enter the marking station for marking, and then enter the next station. Before the parts of the water pump end cover enter the press fitting station, there is a sampling inspection station for quality control

figure 4

1.3 process of water pump end cover assembly branch line

the production beat of water pump end cover assembly branch line is 1 minute, which can be taken directly from (31) centralized pallet without silo, and can work continuously. After the water pump end cover and pressing ring are processed, press fitting is also required. The pressed workpiece (water pump end cover assembly) also needs to be extruded from the annular groove part and fine turning of the inner hole part (considering the press fitting and extrusion deformation, the matching size of the inner hole must be fine turned again). The (41) gantry robot takes the material from the pallet of the (31) centralized chute, and quickly advances it to the waiting area of the lathe. After the lathe completes the processing, it enters the lathe to exchange the processed parts, and then puts the processed parts into the (130) leak detection station. The workpiece is pressed by the leak detection equipment, and the joint is connected to suppress and test the leak, and the unqualified parts are output to the unqualified parts collection box, The qualified parts are pushed into the (45) output chute and transported to the workpiece collection area for final inspection and collection. So far, all processes of the water pump end cover assembly are completed

figure 5

2. Inner and outer bearing assembly production line

inner and outer bearing assembly production line is composed of contact branch line, inner bearing branch line, outer bearing branch line and centralized workpiece detection and collection area. The line is arranged in the order of contact branch line, inner bearing branch line and outer bearing branch line, as shown in Figure 2

2.1 the technological process of the contact branch line

has a beat of 20 seconds, meeting the requirements of 600000 pieces per year (3 contacts need to be welded on an inner bearing). Equipped with a bar conveyor, a single filling can work continuously for more than 10 hours. The special automatic cutting machine is used for automatic feeding, the forming cutter is used to process the conical surface of the end face, and the saw blade cutter is used to cut off. The bar conveyor will directly send the formed bar to the automatic cutting machine for cutting. Before cutting each part, the forming knife will process the conical surface. After processing, it will be transported by (57) to (58) conveyor, and finally to the welding station feeder of the next process

figure 6

2.2 process of outer bearing parts branch line

the production rhythm of outer bearing parts branch line is 1 minute, meeting the requirement of annual output of 200000 pieces. Equipped with a bar building glass visible light transmittance, direct sunlight transmittance, total solar transmittance, ultraviolet transmittance and the determination of relevant window glass parameters gb/t 2680 ⑼ 4 material conveyor, a single filling can work continuously for more than 10 hours

the bar conveyor sends the ring bar material of the outer bearing parts to the lathe for the processing of the first process Op10. After the processing is completed, (71) the tailstock air claw moves to the processing area, the inner support clamps the outer bearing and rotates with the spindle. The machine tool cuts off the processing, and then the tailstock air claw moves away, (71) the manipulator of the gantry robot enters the machine tool to take away the parts on the tailstock air claw and put it into the loading area of the welding station, The robot in the welding station grabs the outer bearing parts to the welding station and positions them, and welds the contacts transported by the contact branch line to the outer bearing. After the welding is completed, the robot in the welding station puts the parts into the loading area of the third process, and the (75) gantry robot, the third process lathe op30 and the fourth process lathe op40 complete the processing of the remaining two processes. There is a turnover station between the third process and the fourth process for turnover, The processed parts enter the (79) output chute and are transported to the workpiece collection area for collection and inspection

Figure 7

2.3 process of inner bearing parts branch line

the production rhythm of inner bearing parts branch line is 1 minute, meeting the requirement of annual output of 200000 pieces. Equipped with a bar conveyor, a single loading can work continuously for more than 10 hours

the bar conveyor sends the ring bar of the inner bearing parts to the lathe for the processing of the first process Op10. After the processing is completed, (89) the tailstock air claw moves

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