阅读说明：本技术 一种球笼制造自动化的模块组合生产工艺 (Automatic module combination production process for manufacturing ball cage ) 是由 蒋楠 李伟 于海波 于 2020-05-21 设计创作，主要内容包括：本发明涉及一种组合生产工艺,尤其涉及一种球笼制造自动化的模块组合生产工艺。按以下步骤进行：上料机操作→正反识别系统操作→提升机操作→数控窗口磨床操作→数控外圆磨床操作→数控内圆磨床操作→自动在线检测操作。配置自动上料、识别、装夹、加工、自动检测、分拣、诊断、报警、保护、通信和呼叫等功能,真正实现了高精度球笼磨削加工自动化和实时高效在线检测的全闭环控制。(The invention relates to a combined production process, in particular to an automatic module combined production process for manufacturing a ball cage. The method comprises the following steps: feeding machine operation → positive and negative recognition system operation → elevator operation → numerical control window grinder operation → numerical control cylindrical grinder operation → numerical control internal grinding machine operation → automatic on-line detection operation. The full-closed loop control of high-precision ball cage grinding machining automation and real-time efficient online detection is really realized by configuring the functions of automatic feeding, identification, clamping, machining, automatic detection, sorting, diagnosis, alarming, protection, communication, calling and the like.)

1. An automatic module combination production process for manufacturing a ball cage is characterized by comprising the following steps:

(I), the operation of a feeding machine:

the product to be processed is placed on a feeding roller platform of a feeding machine, the feeding roller platform is subdivided into 6 material belt supporting plates capable of independently moving back and forth, the tail ends of the material belt supporting plates are connected with a positive and negative recognition system, a photoelectric switch is fixed at the front ends of the material belt supporting plates and is connected with an electric box through a circuit, a PLC (programmable logic controller) is arranged in the electric box, a feeding mechanism is used for orderly arranging and feeding materials in a conveying belt mode and continuously and singly enters a feeding channel of the positive and negative recognition system, qualified feeding is ensured, material jamming or material belt accumulation is avoided, and the effect of protecting the product and a mold on line is further achieved;

(II) operating a positive and negative recognition system:

the positive and negative recognition system consists of a mechanical structure, a vision system, a control system and algorithm software, and a complete working process comprises three steps of workpiece feeding, vision system drawing and calculation and workpiece blanking;

the vision system is the technical core of the positive and negative recognition system and comprises a set of high-pixel area-array cameras and a corresponding light source system; the positive and negative recognition system can automatically distinguish the positive and negative surfaces according to the detection result of the detection system and drive the sorting cylinder to sort the ball cages to the corresponding channels, a set of specially designed overturning structure is arranged in the channel corresponding to the negative surface, and the product is automatically adjusted to be the positive surface when the negative surface enters the channel; the positive and negative identification system has accurate, stable and reliable identification and sorting processes, and can effectively prevent product grinding and scrapping caused by inconsistent positive and negative directions of manual feeding;

(III) elevator operation:

the design of a ring chain structure with less abrasion is adopted, the connection with the slideway type material dividing and blocking structure is very firm, and the device is also suitable for conveying large-size product materials; the elevator adopts the principles of inflow type feeding, induction type discharging and single cycle reciprocating action, so that the phenomena of extrusion and collision between a product and equipment rarely occur, and mechanical abrasion is reduced; the phenomena of material return and material excess during material lifting are effectively avoided, so that the invalid power consumption is low, and the energy is effectively saved; the elevator has good operation reliability, and the advanced design principle and processing method ensure the operation stability and reliability of the whole elevator, thereby achieving higher lifting height;

(IV) operating the numerical control window grinder:

products from a hoister automatically enter a pneumatic workpiece clamping device through a feed inlet sliding rail and a mechanical arm of the numerical control window grinder, the pneumatic workpiece clamping device detects that the products automatically finish product clamping, and a high-frequency electric spindle is started to directly drive an electroplated CBN grinding wheel to grind and process a window;

after the grinding processing is finished, automatically grabbing and moving the product to a discharging slide rail by the manipulator; the manipulator comprises a vertical driving device, a horizontal driving device and a grabbing hand, the grabbing hand is driven by the vertical driving device to move along the vertical direction, and the grabbing hand is driven by the horizontal driving device to move along the horizontal direction; the numerical control window grinder adopts a double-grinding head design, can finish grinding two working faces of an upper window and a lower window of a ball cage respectively by one-time clamping, has high efficiency and stable precision, and is particularly suitable for ball cage window grinding mass production;

(V) operating the numerical control cylindrical grinding machine:

products from the hoister automatically enter the pneumatic workpiece clamping device through a feed inlet sliding rail and a mechanical swing arm of the numerical control cylindrical grinder, and the pneumatic workpiece clamping device detects that the products enter the pneumatic workpiece clamping device to automatically finish product clamping;

the numerical control cylindrical grinding machine selects various diamond dressing devices, realizes the precise dressing of the profile of the complex grinding wheel, automatically compensates, and obviously improves the grinding efficiency and the grinding precision; after the grinding processing is finished, the mechanical swing arm automatically grabs and moves the product to a discharging slide rail; the numerical control cylindrical grinding machine adopts a CNC control system, feeding and finishing are respectively controlled by a servo, and an electromagnetic centerless fixture is used for clamping and a high-rigidity rolling bearing grinding wheel spindle system, so that the numerical control cylindrical grinding machine has good air tightness, and ensures high precision and long service life of a spindle;

(VI) operating the numerical control internal grinding machine:

the product that comes from the lifting machine holds the product of treating processing from feeding slide rail department support to the station through numerical control internal grinding machine's lifting device to fix it on the station firm motionless, after the work piece is accomplished by abrasive machining, lifting device promotes the work piece to ejection of compact slide rail on, makes it export the process down from ejection of compact slide rail: automatic on-line detection; the numerical control internal grinding machine adopts a single-point return type gold steel roller to automatically finish and shape the grinding wheel, so as to ensure the consistency of the spherical curvature and the spherical diameter size; the automatic trimming and automatic compensation of the grinding wheel can reduce the manufacturing cost, improve the production efficiency and ensure the processing precision;

(VII) automatic online detection operation:

the product from the elevator reaches the loading position through the feeding slide rail, and the truss manipulator grabs the product and blows and cleans the surface of the workpiece through the air knife device; the truss mechanical arm grabs the product to the positive and negative recognition system, and directly turns over the product if the product is incorrect in direction, and then grabs the product to a window measuring station to measure the six window reference heights and the window diameters; after the measurement is finished, the truss manipulator grabs the product to an inner spherical surface and outer spherical surface measuring station, and the inner spherical surface diameter, the outer spherical surface diameter, the inner spherical surface curvature and the outer spherical surface curvature are measured respectively; after the measurement is finished, the truss manipulator grabs the qualified products to a discharge slide rail, and rejects the unqualified products to an NG storage bin;

the automatic online detection equipment has the function of counting the total number, the number of qualified products, the number of repaired products and the number of waste products; the automatic online detection equipment reserves a data interface with an MES system, can provide XbarR control chart drawing and a series of process capability control parameters of Cp, Cpk, Pp, Ppk and Cmk according to an SPC process control theory, and monitors long-term or short-term capability indexes of the machining process.

Technical Field

The invention relates to a combined production process, in particular to an automatic module combined production process for manufacturing a ball cage.

Background

Conventional production has weak production capacity and low continuity, so that the operation efficiency is low, the productivity is influenced, and the product quality is also influenced.

Disclosure of Invention

The invention mainly solves the defects in the prior art, and provides the automatic module combination production process for manufacturing the ball cage, which has the advantages of continuous production, further improvement of the productivity and guarantee of the product quality.

The technical problem of the invention is mainly solved by the following technical scheme:

an automatic module combination production process for manufacturing a ball cage comprises the following steps:

(I), the operation of a feeding machine:

the product to be processed is placed on a feeding roller platform of a feeding machine, the feeding roller platform is subdivided into 6 material belt supporting plates capable of independently moving back and forth, the tail ends of the material belt supporting plates are connected with a positive and negative recognition system, a photoelectric switch is fixed at the front ends of the material belt supporting plates and is connected with an electric box through a circuit, a PLC (programmable logic controller) is arranged in the electric box, a feeding mechanism is used for orderly arranging and feeding materials in a conveying belt mode and continuously and singly enters a feeding channel of the positive and negative recognition system, qualified feeding is ensured, material jamming or material belt accumulation is avoided, and the effect of protecting the product and a mold on line is further achieved;

(II) operating a positive and negative recognition system:

the positive and negative recognition system consists of a mechanical structure, a vision system, a control system and algorithm software, and a complete working process comprises three steps of workpiece feeding, vision system drawing and calculation and workpiece blanking;

the vision system is the technical core of the positive and negative recognition system and comprises a set of high-pixel area-array cameras and a corresponding light source system; the positive and negative recognition system can automatically distinguish the positive and negative surfaces according to the detection result of the detection system and drive the sorting cylinder to sort the ball cages to the corresponding channels, a set of specially designed overturning structure is arranged in the channel corresponding to the negative surface, and the product is automatically adjusted to be the positive surface when the negative surface enters the channel; the positive and negative identification system has accurate, stable and reliable identification and sorting processes, and can effectively prevent product grinding and scrapping caused by inconsistent positive and negative directions of manual feeding;

(III) elevator operation:

the design of a ring chain structure with less abrasion is adopted, the connection with the slideway type material dividing and blocking structure is very firm, and the device is also suitable for conveying large-size product materials; the elevator adopts the principles of inflow type feeding, induction type discharging and single cycle reciprocating action, so that the phenomena of extrusion and collision between a product and equipment rarely occur, and mechanical abrasion is reduced; the phenomena of material return and material excess during material lifting are effectively avoided, so that the invalid power consumption is low, and the energy is effectively saved; the elevator has good operation reliability, and the advanced design principle and processing method ensure the operation stability and reliability of the whole elevator, thereby achieving higher lifting height;

(IV) operating the numerical control window grinder:

products from a hoister automatically enter a pneumatic workpiece clamping device through a feed inlet sliding rail and a mechanical arm of the numerical control window grinder, the pneumatic workpiece clamping device detects that the products automatically finish product clamping, and a high-frequency electric spindle is started to directly drive an electroplated CBN grinding wheel to grind and process a window;

after the grinding processing is finished, automatically grabbing and moving the product to a discharging slide rail by the manipulator; the manipulator comprises a vertical driving device, a horizontal driving device and a grabbing hand, the grabbing hand is driven by the vertical driving device to move along the vertical direction, and the grabbing hand is driven by the horizontal driving device to move along the horizontal direction; the numerical control window grinder adopts a double-grinding head design, can finish grinding two working faces of an upper window and a lower window of a ball cage respectively by one-time clamping, has high efficiency and stable precision, and is particularly suitable for ball cage window grinding mass production;

(V) operating the numerical control cylindrical grinding machine:

products from the hoister automatically enter the pneumatic workpiece clamping device through a feed inlet sliding rail and a mechanical swing arm of the numerical control cylindrical grinder, and the pneumatic workpiece clamping device detects that the products enter the pneumatic workpiece clamping device to automatically finish product clamping;

the numerical control cylindrical grinding machine selects various diamond dressing devices, realizes the precise dressing of the profile of the complex grinding wheel, automatically compensates, and obviously improves the grinding efficiency and the grinding precision; after the grinding processing is finished, the mechanical swing arm automatically grabs and moves the product to a discharging slide rail; the numerical control cylindrical grinding machine adopts a CNC control system, feeding and finishing are respectively controlled by a servo, and an electromagnetic centerless fixture is used for clamping and a high-rigidity rolling bearing grinding wheel spindle system, so that the numerical control cylindrical grinding machine has good air tightness, and ensures high precision and long service life of a spindle;

(VI) operating the numerical control internal grinding machine:

the product that comes from the lifting machine holds the product of treating processing from feeding slide rail department support to the station through numerical control internal grinding machine's lifting device to fix it on the station firm motionless, after the work piece is accomplished by abrasive machining, lifting device promotes the work piece to ejection of compact slide rail on, makes it export the process down from ejection of compact slide rail: automatic on-line detection; the numerical control internal grinding machine adopts a single-point return type gold steel roller to automatically finish and shape the grinding wheel, so as to ensure the consistency of the spherical curvature and the spherical diameter size; the automatic trimming and automatic compensation of the grinding wheel can reduce the manufacturing cost, improve the production efficiency and ensure the processing precision;

(VII) automatic online detection operation:

the product from the elevator reaches the loading position through the feeding slide rail, and the truss manipulator grabs the product and blows and cleans the surface of the workpiece through the air knife device; the truss mechanical arm grabs the product to the positive and negative recognition system, and directly turns over the product if the product is incorrect in direction, and then grabs the product to a window measuring station to measure the six window reference heights and the window diameters; after the measurement is finished, the truss manipulator grabs the product to an inner spherical surface and outer spherical surface measuring station, and the inner spherical surface diameter, the outer spherical surface diameter, the inner spherical surface curvature and the outer spherical surface curvature are measured respectively; after the measurement is finished, the truss manipulator grabs the qualified products to a discharge slide rail, and rejects the unqualified products to an NG storage bin;

the automatic online detection equipment has the function of counting the total number, the number of qualified products, the number of repaired products and the number of waste products; the automatic online detection equipment reserves a data interface with an MES system, can provide XbarR control chart drawing and a series of process capability control parameters of Cp, Cpk, Pp, Ppk and Cmk according to an SPC process control theory, and monitors long-term or short-term capability indexes of the machining process.

The module combined production process can realize that 1 worker easily controls 2 pieces of line connecting equipment to carry out automatic production of ball cage window grinding, inner spherical grinding, outer spherical grinding and 100% restraining size detection by connecting and combining the two groups of forward and reverse (mirror direction) lathe lines, and 3 workers are reduced compared with the traditional single-function and cluster type machine tool layout mode. In the existing processing technology, the size precision is generally determined by manually and mechanically measuring a ball cage product processed by a numerical control grinding machine, so that a good product and a defective product are selected, the method belongs to a post-processing control mode, and the batch bad risk exists. In mass production practice, manual measurements exist: large workload, high labor intensity, measurement omission, measurement error and the like. Moreover, because the ball cage products have high requirements for size precision, if a measuring person does not have proper skill or proper detection operation, the accurate detection of whether the products really reach the required size specification cannot be achieved, and therefore, the reliability of the detection result of each ball cage cannot be guaranteed, and the risk of outflow of defective products cannot be avoided all the time.

The module combined production process provides a ball cage automatic grinding processing and online automatic detection scheme, so that the problem of batch quality risk of detection after the traditional ball cage is manufactured is solved, and the problems of low manual detection precision, low detection efficiency and the like are solved. The module is configured with functions of automatic feeding, identification, clamping, processing, automatic detection, sorting, diagnosis, alarming, protection, communication, calling and the like according to the intelligent manufacturing requirement, and the full closed-loop control of high-precision ball cage grinding processing automation and real-time high-efficiency online detection is really realized.

Drawings

FIG. 1 is a flow chart of the apparatus of the present invention.

Detailed Description

The technical scheme of the invention is further specifically described by the following embodiments.