亞洲va在線∨a天堂va歐美va連桿精密鍛造自動化生產線-玉環雙山機械有限公司

工(gong)(gong)(gong)業(ye)(ye)(ye)機(ji)(ji)(ji)器人(ren)(ren)(ren)具有效率高(gao)(gao)、穩定性(xing)(xing)好、可(ke)靠性(xing)(xing)高(gao)(gao)、重(zhong)(zhong)復性(xing)(xing)好、能在(zai)高(gao)(gao)風險環境中(zhong)工(gong)(gong)(gong)作等優點，在(zai)傳統制(zhi)造(zao)(zao)(zao)業(ye)(ye)(ye)尤其(qi)是勞動(dong)密集型產(chan)業(ye)(ye)(ye)的(de)(de)(de)轉型和(he)(he)升級中(zhong)發(fa)揮著越來越重(zhong)(zhong)要(yao)的(de)(de)(de)作用。隨著計算機(ji)(ji)(ji)技(ji)術和(he)(he)工(gong)(gong)(gong)業(ye)(ye)(ye)機(ji)(ji)(ji)器人(ren)(ren)(ren)技(ji)術的(de)(de)(de)飛(fei)速發(fa)展，工(gong)(gong)(gong)業(ye)(ye)(ye)機(ji)(ji)(ji)器人(ren)(ren)(ren)作為裝備制(zhi)造(zao)(zao)(zao)業(ye)(ye)(ye)最(zui)普(pu)遍、最(zui)重(zhong)(zhong)要(yao)的(de)(de)(de)功能部件之一(yi)(yi)，已廣泛應用于汽車(che)工(gong)(gong)(gong)業(ye)(ye)(ye)、航空制(zhi)造(zao)(zao)(zao)業(ye)(ye)(ye)、電(dian)子電(dian)器、現(xian)代物流等大(da)(da)型生(sheng)(sheng)(sheng)產(chan)領域。連(lian)(lian)桿作為發(fa)動(dong)機(ji)(ji)(ji)中(zhong)最(zui)重(zhong)(zhong)要(yao)的(de)(de)(de)零件之一(yi)(yi)，通常是用機(ji)(ji)(ji)械加(jia)工(gong)(gong)(gong)制(zhi)造(zao)(zao)(zao)的(de)(de)(de)鍛(duan)(duan)(duan)件，生(sheng)(sheng)(sheng)產(chan)環境極其(qi)惡劣，對人(ren)(ren)(ren)體危害很大(da)(da)，因此迫切(qie)需(xu)要(yao)進行機(ji)(ji)(ji)器人(ren)(ren)(ren)更換等自動(dong)化(hua)(hua)(hua)改造(zao)(zao)(zao)。王強、袁文(wen)生(sheng)(sheng)(sheng)等人(ren)(ren)(ren)在(zai)精(jing)密鍛(duan)(duan)(duan)造(zao)(zao)(zao)技(ji)術的(de)(de)(de)基(ji)礎(chu)上，設計了(le)(le)連(lian)(lian)桿精(jing)鍛(duan)(duan)(duan)自動(dong)化(hua)(hua)(hua)生(sheng)(sheng)(sheng)產(chan)線。與(yu)原鍛(duan)(duan)(duan)造(zao)(zao)(zao)生(sheng)(sheng)(sheng)產(chan)線相比(bi)，該生(sheng)(sheng)(sheng)產(chan)線提(ti)高(gao)(gao)了(le)(le)鍛(duan)(duan)(duan)造(zao)(zao)(zao)工(gong)(gong)(gong)藝，節省了(le)(le)人(ren)(ren)(ren)力(li)，提(ti)高(gao)(gao)了(le)(le)自動(dong)化(hua)(hua)(hua)程度，提(ti)高(gao)(gao)了(le)(le)連(lian)(lian)桿鍛(duan)(duan)(duan)件的(de)(de)(de)精(jing)度和(he)(he)生(sheng)(sheng)(sheng)產(chan)效率。然(ran)而(er)，該生(sheng)(sheng)(sheng)產(chan)線只實現(xian)了(le)(le)振動(dong)送料、感應加(jia)熱、物料溫度分選到(dao)楔橫軋毛坯的(de)(de)(de)自動(dong)化(hua)(hua)(hua)。其(qi)后期(qi)預鍛(duan)(duan)(duan)、精(jing)鍛(duan)(duan)(duan)、切(qie)邊、沖裁(cai)(cai)、校正(zheng)、沖裁(cai)(cai)等工(gong)(gong)(gong)藝仍需(xu)人(ren)(ren)(ren)工(gong)(gong)(gong)操作，只能生(sheng)(sheng)(sheng)產(chan)最(zui)大(da)(da)鍛(duan)(duan)(duan)件重(zhong)(zhong)量為0.5kg的(de)(de)(de)摩托車(che)發(fa)動(dong)機(ji)(ji)(ji)連(lian)(lian)桿。本文(wen)設計了(le)(le)一(yi)(yi)條全自動(dong)無人(ren)(ren)(ren)駕駛(shi)生(sheng)(sheng)(sheng)產(chan)線，可(ke)生(sheng)(sheng)(sheng)產(chan)出最(zui)大(da)(da)重(zhong)(zhong)量為5kg的(de)(de)(de)汽車(che)發(fa)動(dong)機(ji)(ji)(ji)連(lian)(lian)桿。

1 連桿鍛造工藝

2 自動化生產線

本文(wen)所設(she)計的(de)自動化生(sheng)(sheng)產(chan)線(xian)如圖2所示，共有17臺設(she)備組成，各設(she)備依(yi)次動作(zuo)，彼此(ci)之(zhi)間通過PLC通訊，整條生(sheng)(sheng)產(chan)線(xian)無(wu)需人(ren)工干預(yu)，可(ke)以(yi)生(sheng)(sheng)產(chan)最大重(zhong)量為5kg的(de)汽車發(fa)動機(ji)連桿，生(sheng)(sheng)產(chan)效率最高(gao)可(ke)達9s/件。

2.1 工作流程

圖3為連桿鍛造自動化生產線工作流程圖，從圖中可以看出各設備的工作內容及先后順序：振動分(fen)選給料機(ji)(ji)(ji)負責進料，水平振動給料機(ji)(ji)(ji)將(jiang)(jiang)棒送至(zhi)中頻爐(lu)，中頻感應加熱(re)爐(lu)負責對棒進行(xing)(xing)加熱(re)，紅外(wai)溫(wen)(wen)度計檢測受熱(re)工(gong)(gong)(gong)件(jian)(jian)的(de)溫(wen)(wen)度，物(wu)料溫(wen)(wen)度分(fen)選執行(xing)(xing)器(qi)(qi)根據試驗結果將(jiang)(jiang)棒送至(zhi)指定(ding)位置，自(zi)動輥鍛(duan)(duan)(duan)機(ji)(ji)(ji)以合(he)格溫(wen)(wen)度軋制工(gong)(gong)(gong)件(jian)(jian)，1號機(ji)(ji)(ji)器(qi)(qi)人(ren)在輥鍛(duan)(duan)(duan)后(hou)將(jiang)(jiang)工(gong)(gong)(gong)件(jian)(jian)抓(zhua)取并送至(zhi)1號壓(ya)(ya)(ya)力(li)機(ji)(ji)(ji)。然(ran)后(hou)抓(zhua)取工(gong)(gong)(gong)件(jian)(jian)送到(dao)MP熱(re)模鍛(duan)(duan)(duan)機(ji)(ji)(ji)的(de)預(yu)(yu)鍛(duan)(duan)(duan)站(zhan)。預(yu)(yu)鍛(duan)(duan)(duan)完成后(hou)，2號機(ji)(ji)(ji)器(qi)(qi)人(ren)在預(yu)(yu)鍛(duan)(duan)(duan)站(zhan)抓(zhua)取工(gong)(gong)(gong)件(jian)(jian)，噴涂預(yu)(yu)鍛(duan)(duan)(duan)和(he)精密(mi)(mi)鍛(duan)(duan)(duan)造站(zhan)的(de)脫(tuo)模劑，然(ran)后(hou)將(jiang)(jiang)工(gong)(gong)(gong)件(jian)(jian)置于精鍛(duan)(duan)(duan)站(zhan)。精鍛(duan)(duan)(duan)完成后(hou)，3號機(ji)(ji)(ji)器(qi)(qi)人(ren)在精密(mi)(mi)鍛(duan)(duan)(duan)造站(zhan)抓(zhua)取工(gong)(gong)(gong)件(jian)(jian)，并將(jiang)(jiang)工(gong)(gong)(gong)件(jian)(jian)送至(zhi)2號壓(ya)(ya)(ya)力(li)機(ji)(ji)(ji)。第(di)二壓(ya)(ya)(ya)力(li)機(ji)(ji)(ji)負責沖(chong)(chong)邊(bian)，第(di)四機(ji)(ji)(ji)器(qi)(qi)人(ren)在沖(chong)(chong)邊(bian)后(hou)，抓(zhua)取工(gong)(gong)(gong)件(jian)(jian)并送至(zhi)第(di)三壓(ya)(ya)(ya)力(li)機(ji)(ji)(ji)進行(xing)(xing)校正(zheng)，校正(zheng)完成后(hou)，成品推送機(ji)(ji)(ji)構(gou)將(jiang)(jiang)工(gong)(gong)(gong)件(jian)(jian)推入(ru)沖(chong)(chong)裁滑(hua)(hua)塊(kuai)，工(gong)(gong)(gong)件(jian)(jian)沿沖(chong)(chong)裁滑(hua)(hua)塊(kuai)滑(hua)(hua)到(dao)沖(chong)(chong)裁輸送機(ji)(ji)(ji)上。

值得注意的(de)是，MP熱模鍛(duan)(duan)(duan)壓機(ji)(ji)(ji)上(shang)有兩個工(gong)(gong)位（預(yu)鍛(duan)(duan)(duan)和精(jing)鍛(duan)(duan)(duan)），為節省成本，提高效率，正常(chang)生產時(shi)需要(yao)同時(shi)進行預(yu)鍛(duan)(duan)(duan)和精(jing)鍛(duan)(duan)(duan)，即上(shang)一次鍛(duan)(duan)(duan)壓完成后，3號機(ji)(ji)(ji)器(qi)人(ren)將精(jing)鍛(duan)(duan)(duan)工(gong)(gong)位上(shang)的(de)工(gong)(gong)件抓走，2號機(ji)(ji)(ji)器(qi)人(ren)將預(yu)鍛(duan)(duan)(duan)工(gong)(gong)位上(shang)的(de)工(gong)(gong)件移動到精(jing)鍛(duan)(duan)(duan)工(gong)(gong)位上(shang)，并且 1號機(ji)(ji)(ji)器(qi)人(ren)將拍扁(bian)的(de)工(gong)(gong)件放到預(yu)鍛(duan)(duan)(duan)工(gong)(gong)位上(shang)后，熱模鍛(duan)(duan)(duan)壓機(ji)(ji)(ji)才開始鍛(duan)(duan)(duan)壓生產。

2.2 主要設備簡介

從圖3中可以看出，連桿鍛造自(zi)動(dong)化(hua)生產(chan)線上(shang)的設備(bei)主要分(fen)為4部分(fen)：自(zi)動(dong)上(shang)料系統，感應加(jia)熱及分(fen)選系統，鍛造設備(bei)和自(zi)動(dong)化(hua)設備(bei)。

2.2.1 自動上料系統

自動(dong)(dong)上料(liao)系統由振動(dong)(dong)排序上料(liao)機和(he)水平(ping)振動(dong)(dong)給料(liao)機組(zu)成，其主(zhu)要(yao)功能和(he)動(dong)(dong)作如下：

(1)將毛坯慢慢倒進振動分選給料機的料斗中。在振動電機的作用下，毛坯沿料斗內壁的螺旋材料通道向上爬，并在上升過程中自動排序。
(2)送(song)料口(kou)通過水平振(zhen)動給料機與(yu)中頻(pin)感(gan)(gan)應(ying)加(jia)熱(re)(re)爐進料裝(zhuang)置的入(ru)口(kou)連接，按預定節拍(pai)順序將毛坯送(song)入(ru)感(gan)(gan)應(ying)加(jia)熱(re)(re)線圈，實現中頻(pin)爐進料過程的自動化。

當上料(liao)機料(liao)斗內的坯料(liao)小于設定(ding)值時，控制(zhi)系統(tong)發出缺(que)料(liao)報(bao)警(jing)信號，通知巡視工人進(jin)行下(xia)一次加料(liao)。

2.2.2 感應加熱及分選系統

感應加(jia)熱(re)及分(fen)選系統(tong)主(zhu)要由(you)中(zhong)頻(pin)感應加(jia)熱(re)爐(lu)、紅外測溫儀、分(fen)選執行機構和廢料(liao)筐(kuang)組成。

中頻感應(ying)(ying)加熱(re)爐的(de)(de)額定(ding)功(gong)率為460kW，實際加熱(re)功(gong)率根據(ju)毛坯(pi)重量和(he)(he)生產節(jie)拍(pai)確定(ding)。為了(le)適(shi)應(ying)(ying)不(bu)同直徑毛坯(pi)的(de)(de)加熱(re)要求，感應(ying)(ying)加熱(re)線(xian)(xian)圈部件(jian)采用了(le)快換接頭(tou)，可實現不(bu)同規格線(xian)(xian)圈之(zhi)間(jian)的(de)(de)快速更(geng)換。加熱(re)線(xian)(xian)圈入口處(chu)安裝(zhuang)有(you)滾壓輪推(tui)料機(ji)構(gou)，與水平振(zhen)動(dong)給料機(ji)的(de)(de)出口銜(xian)接，出口處(chu)安裝(zhuang)有(you)紅外測溫(wen)儀和(he)(he)料溫(wen)分(fen)選執行機(ji)構(gou)，分(fen)選執行機(ji)構(gou)下方有(you)三條可切換的(de)(de)通道，分(fen)別是正常料道、過燒料道和(he)(he)欠溫(wen)料道。

根據連桿(gan)型號的不同，設(she)定相應的始鍛(duan)(duan)溫(wen)(wen)度范(fan)圍，并將溫(wen)(wen)度上、下(xia)臨(lin)(lin)界(jie)(jie)值輸入(ru)到控制(zhi)系(xi)統內(nei)。若(ruo)紅外測(ce)溫(wen)(wen)儀(yi)測(ce)出的料(liao)(liao)溫(wen)(wen)高于上臨(lin)(lin)界(jie)(jie)值，則毛(mao)坯(pi)(pi)過(guo)燒，執(zhi)(zhi)行機構(gou)啟動過(guo)燒料(liao)(liao)道(dao)使(shi)毛(mao)坯(pi)(pi)進入(ru)廢料(liao)(liao)筐。若(ruo)料(liao)(liao)溫(wen)(wen)低(di)于下(xia)臨(lin)(lin)界(jie)(jie)值，則毛(mao)坯(pi)(pi)欠溫(wen)(wen)，執(zhi)(zhi)行機構(gou)切換到欠溫(wen)(wen)通道(dao)，使(shi)毛(mao)坯(pi)(pi)進入(ru)回收(shou)箱。回收(shou)箱內(nei)的毛(mao)坯(pi)(pi)可再次加(jia)熱使(shi)用。只有料(liao)(liao)溫(wen)(wen)在設(she)定范(fan)圍內(nei)的毛(mao)坯(pi)(pi)，才能通過(guo)正常通道(dao)輸送到輥(gun)鍛(duan)(duan)工位。整個料(liao)(liao)溫(wen)(wen)分選過(guo)程是自動完成(cheng)的，嚴格的料(liao)(liao)溫(wen)(wen)控制(zhi)措施為確(que)保連桿(gan)鍛(duan)(duan)造質(zhi)量提供了可靠的保障。

2.2.3 鍛造設備

鍛(duan)造(zao)設備包括1臺(tai)(tai)輥鍛(duan)機(ji)(ji)，3臺(tai)(tai)高(gao)性能壓力機(ji)(ji)和1臺(tai)(tai)熱模鍛(duan)壓機(ji)(ji)，負責連桿(gan)的鍛(duan)造(zao)成形(xing)。

輥(gun)鍛(duan)機設有中(zhong)心距調節(jie)機構(gou)、氣(qi)(qi)動(dong)間(jian)隙補償機構(gou)、氣(qi)(qi)動(dong)摩擦離合器和制(zhi)(zhi)動(dong)器、自動(dong)干油潤滑等。機械手(shou)夾(jia)具采用伺服電機和球桿(gan)結構(gou)水平移動(dong)，夾(jia)持用旋轉(zhuan)(zhuan)(zhuan)缸代替直桿(gan)缸旋轉(zhuan)(zhuan)(zhuan)，并提供一(yi)套油溫和過濾(lv)控制(zhi)(zhi)系統。采用連續旋轉(zhuan)(zhuan)(zhuan)成形工藝(yi)(yi)對圓(yuan)棒進行粗鍛(duan)。它(ta)具有鍛(duan)造(zao)精度高(gao)、節(jie)能、生產率高(gao)、模具壽命長等優點，能夠(gou)實現軋(ya)制(zhi)(zhi)過程(cheng)的自動(dong)化。它(ta)是(shi)一(yi)種更(geng)換工藝(yi)(yi)和設備來更(geng)換氣(qi)(qi)錘坯。

輥(gun)鍛機之后是1號高性(xing)能壓力機，負責對輥(gun)鍛件進行拍扁。

MP熱模(mo)(mo)鍛(duan)(duan)壓(ya)(ya)(ya)機設(she)有(you)預鍛(duan)(duan)和(he)精(jing)鍛(duan)(duan)兩(liang)個(ge)工(gong)位，具有(you)精(jing)度高，剛度大(da)，抗偏載能力強等(deng)(deng)特點(dian)，打(da)(da)擊過程可(ke)實現(xian) PLC控制(zhi)，能夠精(jing)確控制(zhi)打(da)(da)擊能量、打(da)(da)擊次數(shu)、兩(liang)次打(da)(da)擊之間的(de)時間間歇等(deng)(deng)參數(shu)，操作(zuo)安(an)全可(ke)靠，鍛(duan)(duan)件質量基本不受工(gong)人操作(zuo)水(shui)平的(de)影(ying)響，從(cong)而為實現(xian)連桿精(jing)密(mi)鍛(duan)(duan)造提供了可(ke)靠的(de)設(she)備(bei)保障。該(gai)設(she)備(bei)還具備(bei)參數(shu)存儲(chu)、故(gu)障報警及自動(dong)診斷等(deng)(deng)功能。熱模(mo)(mo)鍛(duan)(duan)壓(ya)(ya)(ya)機之后是2號(hao)(hao)高性(xing)能壓(ya)(ya)(ya)力機，其上安(an)裝有(you)復合模(mo)(mo)具，負(fu)責切(qie)邊和(he)沖孔(kong)。2號(hao)(hao)壓(ya)(ya)(ya)力機后是3號(hao)(hao)壓(ya)(ya)(ya)力機，負(fu)責對切(qie)邊沖孔(kong)的(de)工(gong)件進行校正。

2.2.4 自動化設備

自(zi)動化設備(bei)包括(kuo)3臺FANUC M-710iC/50鑄造版(ban)機器人(ren)（1、3、4 號）、1 臺 FANUC R-2000iC/165F（2號機器人(ren)）鑄造版(ban)機器人(ren)和1臺成品推送機構(gou)。代替人(ren)工完成工件從一臺設備(bei)流轉到下(xia)一臺設備(bei)的工作。

1號(hao)(hao)機(ji)(ji)器(qi)人負責從輥鍛(duan)(duan)機(ji)(ji)抓取(qu)輥鍛(duan)(duan)后(hou)(hou)的工(gong)(gong)件(jian)(jian)(jian)放(fang)到(dao)1號(hao)(hao)壓力機(ji)(ji)上，等待1號(hao)(hao)壓力機(ji)(ji)對工(gong)(gong)件(jian)(jian)(jian)進行拍扁，拍扁完成后(hou)(hou)，1號(hao)(hao)機(ji)(ji)器(qi)人再(zai)將(jiang)工(gong)(gong)件(jian)(jian)(jian)抓起，送(song)到(dao)熱(re)模(mo)(mo)鍛(duan)(duan)壓機(ji)(ji)預(yu)(yu)鍛(duan)(duan)工(gong)(gong)位(wei)上。2號(hao)(hao)機(ji)(ji)器(qi)人負責在鍛(duan)(duan)造完成后(hou)(hou)將(jiang)熱(re)模(mo)(mo)鍛(duan)(duan)壓機(ji)(ji)預(yu)(yu)鍛(duan)(duan)工(gong)(gong)位(wei)上的工(gong)(gong)件(jian)(jian)(jian)抓起，對預(yu)(yu)鍛(duan)(duan)和精鍛(duan)(duan)工(gong)(gong)位(wei)噴脫模(mo)(mo)劑，然后(hou)(hou)再(zai)將(jiang)工(gong)(gong)件(jian)(jian)(jian)放(fang)到(dao)精鍛(duan)(duan)工(gong)(gong)位(wei)上。3號(hao)(hao)機(ji)(ji)器(qi)人負責抓取(qu)熱(re)模(mo)(mo)鍛(duan)(duan)壓機(ji)(ji)精鍛(duan)(duan)模(mo)(mo)具的工(gong)(gong)件(jian)(jian)(jian)放(fang)到(dao)切邊沖孔壓力機(ji)(ji)上。4號(hao)(hao)機(ji)(ji)器(qi)人負責從切邊沖孔壓力機(ji)(ji)上抓取(qu)工(gong)(gong)件(jian)(jian)(jian)，放(fang)到(dao)校正壓力機(ji)(ji)上。成品推送(song)機(ji)(ji)構負責將(jiang)校正后(hou)(hou)的工(gong)(gong)件(jian)(jian)(jian)推到(dao)下料滑(hua)道(dao)(dao)內(nei)，使工(gong)(gong)件(jian)(jian)(jian)沿滑(hua)道(dao)(dao)移動(dong)至下料筐內(nei)。

3 結語

以(yi)連桿精(jing)鍛(duan)技術為基(ji)礎，研制(zhi)了一條自動(dong)(dong)精(jing)鍛(duan)生產(chan)線，可用于生產(chan)長軸精(jing)密鍛(duan)件，如振(zhen)動(dong)(dong)進給、感應(ying)加熱、物(wu)料溫(wen)度分選、拍擊、預鍛(duan)、精(jing)鍛(duan)、刀刃沖(chong)孔(kong)及沖(chong)裁校正等。它具(ju)有節能、節約材料、效(xiao)率高(gao)、產(chan)品精(jing)度高(gao)、質量好、自動(dong)(dong)化程度高(gao)、安全可靠(kao)等優(you)點，是取代傳(chuan)統連桿鍛(duan)件生產(chan)設(she)備的替代產(chan)品。該生產(chan)線已投入使用，取得了良好的經(jing)濟效(xiao)益。