Full-automatic packaging system of three way catalyst converter

文档序号：1898123 发布日期：2021-11-30 浏览：11次中文

阅读说明：本技术 一种三元催化器全自动封装系统 (Full-automatic packaging system of three way catalyst converter ) 是由张勇李芳昕焦新生许腾云杨帅祈佩张秋华岳义于 2021-08-04 设计创作，主要内容包括：本发明提供一种三元催化器全自动封装系统,包括人机操作界面、总控系统、壳体输送装置、壳体上料装置、壳体测量装置、不合格壳体下料装置、壳体机器人、壳体压装定位装置、衬垫输送装置、衬垫抓取装置、衬垫测量装置、衬垫定位装置、不合格衬垫下料装置、载体输送装置、载体上料装置、载体测量装置、不合格载体下料装置、载体机器人、包裹装置、包裹体过渡装置、压装装置、缩径装置、成品机器人、成品打标装置、成品测量装置、不合格成品下料装置和码垛机器人。本发明提供的三元催化器全自动封装系统在自动封装过程中各散件、成品数据均有详细记录,关键环节加入判断,能有效防止人工上料的失误。(The invention provides a full-automatic packaging system of a three-way catalyst, which comprises a human-computer operation interface, a master control system, a shell conveying device, a shell feeding device, a shell measuring device, an unqualified shell discharging device, a shell robot, a shell press-fitting positioning device, a liner conveying device, a liner grabbing device, a liner measuring device, a liner positioning device, an unqualified liner discharging device, a carrier conveying device, a carrier feeding device, a carrier measuring device, an unqualified carrier discharging device, a carrier robot, a wrapping device, an inclusion transition device, a press-fitting device, a diameter reducing device, a finished product robot, a finished product marking device, a finished product measuring device, an unqualified finished product discharging device and a stacking robot. The full-automatic packaging system for the three-way catalytic converter has the advantages that data of all parts and finished products are recorded in detail in the automatic packaging process, judgment is added in key links, and errors of manual feeding can be effectively prevented.)

1. A full-automatic packaging system of a three-way catalyst is characterized by comprising a human-computer operation interface, a master control system, a shell conveying device, a shell feeding device, a shell measuring device, an unqualified shell discharging device, a shell robot, a shell press-fitting positioning device, a liner conveying device, a liner grabbing device, a liner measuring device, a liner positioning device, an unqualified liner discharging device, a carrier conveying device, a carrier feeding device, a carrier measuring device, an unqualified carrier discharging device, a carrier robot, a wrapping device, a wrapping body transition device, a press-fitting device, a diameter reducing device, a finished product robot, a finished product marking device, a finished product measuring device, an unqualified finished product discharging device and a stacking robot;

the human-computer operation interface is used for sending instructions on the interface, monitoring the state of the system and checking or editing the human-computer interaction of the database, wherein the instructions comprise manual instructions and automatic operation instructions of the whole set of equipment;

the master control system is used for carrying out logic control on the whole system, setting a motion time sequence according to signals of each sensor or time control quantity and controlling the whole system to efficiently operate according to beats;

the shell conveying device is used for conveying the shells placed on the conveying belt to a specified position;

the shell feeding device is used for taking the shell at the tail end of the conveying belt to the measuring device;

the shell measuring device is used for measuring shell parameters and executing recording and judgment according to the measurement result, consists of a rotary table and a plurality of measuring devices, and has the functions of diameter measurement, characteristic element detection and positioning and product code reading;

the unqualified shell blanking device is used for taking the unqualified shell off line;

the shell press-fitting positioning device is used for fixing the shell on the press-fitting device;

the liner conveying device is used for storing and conveying liners;

the liner grabbing device is used for grabbing the liner out of the conveying device and has the functions of judging the front and back of the liner and measuring the distance from the grabber to the liner;

the pad measuring device is used for measuring pad related data;

the liner positioning device is used for placing the liner to a specified position;

the unqualified liner blanking device is used for placing unqualified liners into an unqualified product storage tank;

the carrier conveying device is used for conveying the carriers placed on the conveying belt to a specified position, and two conveying belts are used, so that the packaging requirements of the single-carrier and double-carrier catalysts can be met by using the same process;

the carrier feeding device is used for taking the carrier at the tail end of the conveying belt to the measuring device;

the carrier measuring device is used for measuring the parameters of the shell and recording and judging according to the measurement result, consists of a rotary table and a plurality of measuring devices, and has the functions of measuring the diameter and reading the product code;

the unqualified carrier blanking device is used for offline unqualified carriers;

the wrapping device is used for wrapping the liner on the carrier and is a mould which is replaced according to the model;

the inclusion transfer device is used for transferring the inclusions in the inclusion transfer device to the press device;

the carrier robot, the tongs are installed to the end, carries out two kinds of functions: firstly, the qualified carrier which is measured is sent to a press-mounting fixed position; secondly, taking the carrier which is measured to be unqualified to an unqualified carrier conveyer belt;

the press-fitting device is used for pressing the inclusion into the shell;

the shell robot, the tongs are installed to the end, carries out three kinds of functions: one of the shell pressing positioning devices is used for taking the qualified shell from the measuring device to the shell pressing positioning device; secondly, in order to meet the technological requirements, turning around the shell which completes the primary press mounting so as to carry out secondary press mounting; thirdly, taking the press-fitting body from the shell press-fitting positioning device to a diameter reducing device for diameter reduction;

the reducing device is matched with a plurality of sets of reducing dies for use and is used for reducing or reducing the diameter of the press-fitting body according to the process requirements;

the tail end of the finished product robot is provided with a gripper which is used for taking out a finished product from the pipe reducing machine and placing the finished product on a workbench of a finished product marking device;

the finished product marking device is used for engraving a mark on the finished product subjected to diameter reduction and reading the code by a code reader after the marking is finished;

the finished product measuring device is used for measuring the diameter of a finished product and executing recording and judgment according to the measuring result;

the unqualified finished product blanking device is used for offline unqualified finished products;

the qualified finished product stacking device comprises a stacking robot and a stacking tray, and the measured qualified finished products are taken away by the stacking robot and stacked on the stacking tray.

2. The full-automatic packaging system of the three-way catalyst as claimed in claim 1, characterized in that the working principle is as follows:

preparing raw materials by an operator, placing the raw materials into each feeding port, setting parameters on a human-computer operation interface, and starting a system; the master control system sends control instructions to the subsystems;

the shell conveying device conveys the shell to the tail end of the conveying belt, the sensor sends a signal to the master control system, the conveying belt stops, the manipulator of the shell feeding device moves to a material taking position, and the shell conveying belt advances by one workpiece position; a manipulator of the shell feeding device moves to an appointed position according to the shell reminding number, and a gripper grabs the shell and places the shell on the shell measuring device; a plurality of measuring sensors of the shell measuring device work, corresponding measuring data are uploaded to the main control system, the main control system is compared with data in a database, error proofing and recording operations are carried out, and relevant information is recorded in the database; when the measurement of the shell is finished and error information is reported, the shell is clamped to the unqualified shell blanking device by a manipulator of the shell feeding device, a sensor on the conveying belt moves a workpiece position after detecting a material signal, and when a sensor at the tail end of the conveying belt detects the signal, a full-load signal is sent to a master control system to prompt a worker to take off an unqualified product; when the measurement of the shell is finished and no error information is reported, the shell robot grabs the shell from the rotary table, performs appropriate posture adjustment according to process requirements, places the shell on a shell press-fitting positioning device, realizes circumferential and axial positioning by a tool, triggers a sensor and then sends a shell fixing in-place signal to a master control system, and returns to zero;

the liners are stored in material frames of the liner conveying device, each material frame is provided with two material grooves, and the liner feeding requirements of single-carrier and double-carrier matching can be met by using the same process; the master control system sends an instruction, the gripper of the liner grabbing device moves to the upper side of the liner trough, the sensor measures the distance from the gripper to the liner when grabbing the liner, the gripper automatically moves in place to grab the liner, the vision sensor judges whether the liner is misplaced in the front or back direction, the liner is conveyed to the liner measuring device according to the result, relevant data of the liner are measured and sent to the master control system, the data are compared with the data in the database, and whether measured values of the liner are in a qualified range is judged; if the liner is qualified, the liner positioning device moves the qualified liner from the measuring table to the liner lifting frame, the lifting frame falls down, and the qualified liner is placed on the wrapping device; how to disqualify, the pad is placed into a disqualified product storage tank by a pad gripper of a disqualified pad blanking device, the master control system counts, and when the quantity limit is reached, the master control system reminds workers to clean the disqualified products;

the carrier is placed on the carrier conveying device by workers, the conveying belt has a temporary storage function, and the two lines are parallel; when the carrier reaches the tail end of the conveying belt, a sensor sends a signal to a master control system, the conveying belt stops, a manipulator of the carrier feeding device moves to a material taking position, and the carrier conveying device moves forward by a workpiece position; the carrier feeding device takes materials on the two conveying lines in turn, and the same process can be used for simultaneously meeting the packaging requirements of the single-carrier and double-carrier catalysts; the carrier loading device grabs the carrier, the carrier is placed on the carrier measuring device, the measuring sensor works, data are uploaded to the master control system, and data comparison, error-proofing judgment and calculation are carried out according to setting; a code reader of the carrier measuring device moves up and down to a designated position, the carrier code is read, relevant information is recorded in a database, and if the code cannot be read, an error signal is sent; when an error signal is reported, the carrier robot clamps the shell to the unqualified carrier discharging device, the sensor on the carrier robot moves a workpiece position after detecting a material signal, and when the sensor at the tail end of the unqualified carrier discharging device detects the signal, a full load signal is sent to a master control system to prompt a worker to take off an unqualified product; after the carrier is measured to be qualified, the carrier is taken by a carrier robot and placed on a wrapping device, the liner is placed on the wrapping device at the moment, the carrier is pressed downwards and limited by a die tool, the liner forms half-surrounding to the carrier, and the wrapping device wraps the liner placed on the carrier completely along the carrier; an inclusion pushing machine of the inclusion transition device restrains the inclusion in the fixing tool and conveys the inclusion to the press-fitting device; the press-fitting device presses the inclusion into the shell through the tool; taking out the press-fitting body by a shell robot, placing the press-fitting body on a working platform of a diameter reducing device, adjusting the position of the platform to enable the press-fitting body to reach an appointed position, and carrying out diameter reducing or diameter reducing shrinkage and mouth shaping by the diameter reducing device according to process requirements, wherein a specific process and a diameter-determining value are determined by database parameters, and the diameter-reducing value is calculated by measured bulk measurement data and a GBD (guaranteed bit rate) calculation formula; taking out the finished product by a finished product robot, and placing the finished product on a platform of a finished product marking device; the finished product marking device sets a marking code according to the database, reads the code by a code reader after the marking is finished, and prompts that the marking code is invalid if the marking code is unsuccessful, and judges that the marking code is not qualified; successfully reading and uploading the data to a total control system, placing the finished product on a rotary table of a finished product measuring device by a palletizing robot, measuring the diameter of the finished product by a photoelectric sensor, separately measuring the double-carrier finished product at two packaging carriers, uploading the data to the total control system, calculating a GBD value according to a GBD calculation formula, and checking whether the GBD value is within a qualified value range; the method comprises the following steps that a finished product which is invalid in code printing and unqualified in detection is conveyed onto an unqualified finished product conveying belt by an unqualified finished product discharging device, a sensor on the conveying belt moves a workpiece position after detecting a material signal, and when a sensor at the tail end of the conveying belt detects the signal, a full-load signal is sent to a master control system to prompt a worker to take the unqualified product away; the qualified finished products are taken away by the stacking robot and stacked on the trays, the master control system counts, and when the given number is reached, workers are reminded to replace the trays;

all the processes are controlled according to given beats and run synchronously, and the full-automatic packaging of the three-way catalytic converter is realized.

3. The full-automatic packaging system of the three-way catalyst as claimed in claim 1, wherein in the shell conveying device, the conveying belt has a temporary storage function, the shell reaches the end of the conveying belt, the sensor sends a signal to the master control system, the conveying belt stops, the master control system sends an instruction to enable the shell feeding device to move to a taking position to take the shell, after the shell is taken away, the signal of the sensor changes, and the shell conveying belt advances by one workpiece position.

4. The full-automatic packaging system of the three-way catalyst as claimed in claim 1, wherein the shell feeding device is a paw with multi-directional movement capability, the position of the clamping shell can be adjusted according to the model of the shell, the device moves after receiving a command sent by a master controller, and the movement position of each shaft is read from a database; the paw is suitable for the casing of multiple dimensions to have empty clamp error reporting function.

5. The full-automatic packaging system of the three-way catalyst as claimed in claim 1, wherein the shell measuring device has a diameter measuring function, is measured by the photoelectric sensor, uploads data to the master controller, and is compared with data in the database for error prevention;

the shell measuring device has a characteristic element measuring function, is measured by a visual sensor, the visual sensor is arranged on the mobile module, the position can be adjusted according to the size of the shell, after the shell reaches the position appointed by the database, the appointed element on the shell is detected, the corner position of the rotary table is recorded when the elements are matched, and an error is prompted when the elements are not matched;

the shell measuring device has a characteristic element positioning function, and after the vision sensor finishes the measurement of the specified element, the vision sensor can rotate the characteristic to the specified position according to the process requirement so as to meet the subsequent process requirement;

the shell measuring device has a product code reading function and is executed by a code reader, the code reader is arranged on the mobile module, the position can be adjusted according to the size of the shell, after the position reaches the specified position of the database, the code on the shell is read, relevant information is recorded in the database, and if the code cannot be read at the specified position, the error placement of the carrier is prompted.

6. The three-way catalyst full-automatic packaging system of claim 1, wherein the unqualified shell/carrier/finished product blanking device is used for clamping the shell/carrier/finished product onto the unqualified conveyer belt by a mechanical arm after the shell/carrier/finished product measuring device sends out error reporting information, a sensor on the conveyer belt moves a workpiece position after detecting a material signal, and a sensor at the tail end of the conveyer belt sends a full load signal to a master controller after detecting the signal to prompt a worker to take the unqualified product away.

7. The full-automatic packaging system of the three-way catalyst, according to claim 1, characterized in that the shell press-fitting positioning device comprises a circumference positioning device and a tail end positioning device, the circumference positioning device is adapted to shells with different sizes by changing a mold, and the tail end positioning device is assigned to a positioning position by the master control.

8. The full-automatic three-way catalyst packaging system of claim 1, wherein the mat conveyor is used for storing and conveying mats; the liner is stored in the material frame, and each material frame is provided with two material troughs, so that the liner loading requirements of single-carrier and double-carrier matching can be met.

9. The full-automatic packaging system of the three-way catalyst according to claim 1, wherein the gasket grabbing device places the gasket which is not reported to be wrong on the gasket measuring device and places the wrong gasket in a defective material frame according to the general control instruction;

the liner grabbing device judges whether the front and the back of the liner are misplaced or not by the vision sensor before grabbing the liner, and sends an instruction to the master controller;

and the pad gripping device measures the distance from the gripper to the pad by the sensor when gripping the pad, and the gripper automatically moves to the position to grip the pad.

10. The full-automatic packaging system for the three-way catalyst according to claim 1, wherein the gasket measuring device is used for measuring that the gasket gripping device places qualified gaskets on the measuring table, measuring relevant data of each gasket and sending the relevant data to the general control, and judging whether each measured value of the gasket is in a qualified range.

11. The full-automatic three-way catalyst packaging system of claim 1, wherein the liner positioning device, which is used for placing the liner at a designated position, comprises a liner moving module and a liner lifting frame, wherein the liner moving module moves the liner from the measuring table to the lifting frame, the lifting frame falls down, and the liner is placed on the wrapping machine.

12. The full-automatic three-way catalyst packaging system of claim 1, wherein the unqualified gasket blanking device comprises a gasket gripper and an unqualified gasket storage tank, the detected unqualified gasket is gripped by the gasket gripper and placed in the unqualified product storage tank, the system counts, and when the number limit is reached, the system reminds workers to clean the unqualified product.

13. The full-automatic packaging system of the three-way catalyst as claimed in claim 1, wherein the carrier conveying device is used for conveying the carriers placed on the conveying belt to a designated position, the conveying belts are two, independently operate and have a temporary storage function, the carriers reach the tail end of the conveying belt, a sensor sends a signal to the master control system, the conveying belt stops, the carrier loading manipulator moves to a material taking position, and the carrier conveying belt advances by one workpiece position; the carrier feeding mechanical arm takes materials on the two conveying lines in turn, and the packaging requirements of the single-carrier and double-carrier catalysts can be met by using the same process.

14. The full-automatic packaging system of the three-way catalyst, according to claim 1, characterized in that the carrier loading device is used for taking the carrier at the tail end of the conveyer belt to the measuring device, the carrier loading device is a paw with multi-direction movement capability, the position for clamping the carrier can be adjusted according to the type of the carrier, the device moves after receiving the instruction sent by the master controller, and the movement position of each shaft is read from a database; the paw is suitable for the casing of multiple dimensions to have empty clamp error reporting function.

15. The full-automatic three-way catalyst packaging system of claim 1, wherein the wrapping device for wrapping the mat on the carrier is a mold that is changed according to model; the liner is placed on the wrapping device by the liner positioning device after being measured qualified, the carrier is taken to the space above the wrapping machine by the carrier robot after being measured qualified, the liner is pressed downwards, under the limitation of a tooling of the wrapping device, the liner is semi-surrounded on the carrier, and then the wrapping device wraps the liner completely along the carrier.

16. The full-automatic three-way catalyst packaging system of claim 1, wherein the inclusion transfer device comprises an inclusion pusher and a transition cylinder for transferring the inclusions in the inclusion transfer device to the press device; the inclusion pusher, the inclusion device and the transition cylinder are coaxial at first, the inclusion pusher pushes the inclusion into the transition cylinder from the inclusion device, the pusher returns, the transition cylinder moves, and the inclusion is moved to the press-fitting device.

17. The full-automatic three-way catalyst packaging system of claim 1, wherein the press-fitting device is used for pressing the inclusion into the shell; the press-fitting device consists of a press-fitting machine and a press-fitting cylinder, wherein the press-fitting cylinder is a die which is replaced according to the model; after the transition cylinder moves to the press-mounting station, the press-mounting machine, the transition cylinder, the press-mounting cylinder and the shell fixed by the shell press-mounting positioning device are positioned on the same axis, the press-mounting machine moves to push the inclusion in the transition cylinder into the press-mounting cylinder, and the inclusion is further pushed into the shell through the guidance of the press-mounting cylinder to form a press-mounting body; the motion parameters of the press are given by a database.

18. The full-automatic packaging system of the three-way catalyst as claimed in claim 1, wherein the finished product marking device is composed of a moving module, a marking machine, a code reader and a rotary table, and is used for engraving marks on the finished product with reduced diameter, and the content and the form of the marks are specified in a database by a craftsman; the finished product is placed on a rotary table, the marking machine is fixed on the movable module, the finished product can be moved to a designated position according to requirements, the marking is set according to a database, and after the marking is finished, the code is read by a code reader; and uploading the data to the master controller successfully after reading, and prompting that the code printing is invalid unsuccessfully.

19. The full-automatic packaging system for the three-way catalyst as claimed in claim 1, wherein the finished product measuring device is composed of a mobile module, a photoelectric sensor and a rotary table, the finished product is placed on the rotary table, the rotary table is rotated, the diameter of the finished product is measured by the photoelectric sensor, the finished product is separately measured at two packaging carriers for a double-carrier finished product, data is uploaded to a master controller, a GBD value is calculated according to a GBD calculation formula, and whether the finished product is in a qualified value range is checked.

20. The three-way catalyst full automatic packaging system of claim 1, wherein the MES system is accessible.

Technical Field

The invention relates to the technical field of three-way catalyst encapsulation, in particular to a full-automatic encapsulation system of a three-way catalyst.

Background

The three-way catalytic converter is a commonly used engine tail gas treatment device at present, and is formed by combining a carrier, a gasket and a shell, wherein a coating is attached to the carrier, the carrier is of a porous structure and is a core component for carrying out tail gas chemical reaction to remove harmful gas, the shell is used for protecting the carrier, and the gasket between the shell and the carrier plays a role in protection and buffering. With the improvement of environmental protection standards, the form of the three-way catalyst is continuously changed, the packaging process is also changed, and the application of the industrial robot in a packaging system helps to realize the automation, flexibility and informatization of packaging.

The patent CN103726913A discloses a three-way catalyst assembly for automobile and a manufacturing and packaging process thereof, wherein the packaging process comprises the steps of coiling, rolling, loading, necking, welding, pressing, assembling and air tightness test.

Patent CN106697423A discloses an automatic sizing type three-way catalyst packaging system, which comprises a main controller, an automatic shell conveying device in communication connection with the main controller, an automatic liner conveying device in communication connection with the main controller, an automatic carrier conveying device in communication connection with the main controller, a numerical control diameter reducing device, a GBD measuring device, a lettering device, a necking device and a detecting device, wherein the automatic shell conveying device, the automatic liner conveying device, the automatic carrier conveying device, the numerical control diameter reducing device, the GBD measuring device, the lettering device, the necking device and the detecting device are arranged to realize the automatic packaging system of the three-way catalyst, and meanwhile, a carrier size detecting device and a liner weight detecting device are arranged, the GBD detecting device calculates the shell size meeting the GBD requirement according to the carrier size and the liner weight, and then transmits the data to the control end of the numerical control diameter reducing device, the sizing is on a shell with carrier size and liner density matching and meets the manufacturing process validation standard that GBD deviation is less than 8%.

With the improvement of environmental protection standards, the market puts forward requirements on the packaging of the three-way catalytic converter, such as high efficiency, high precision, high flexibility, informatization and the like. Firstly, the requirement for controlling the gap of the gasket in the packaging process of the three-way catalyst is higher and higher, the shell, the carrier and the gasket have processing errors, the parts must be measured to realize diameter changing or diameter reducing and pipe shrinking to ensure that the gap of the three-way catalyst produced in large scale is controlled in a high-precision range, and the quality requirement is difficult to ensure only by means of manual wrapping, press fitting and the like in the processes. Second, the three-way catalyst is increasingly produced in a variety of products, and high flexibility is required for the packaging apparatus. Thirdly, each assembly plant has increasingly high requirements for product traceability, especially for core carriers. Fourthly, as the labor cost is increased continuously, the requirement of the three-way catalyst on the packaging of people is higher and higher, the packaging operation is not suitable for a large number of workers, and the use of a robot and an automatic special machine becomes necessary. In conclusion, the existing three-way catalyst packaging system has the defects that the packaging requirement under the requirement of a new environmental protection standard is not met.

Disclosure of Invention

The invention aims to provide a full-automatic packaging system of a three-way catalyst, which aims to solve the problem that the quality control requirement of the three-way catalyst cannot meet the requirement of a new environmental protection standard in the existing packaging process and realize automation, informatization and flexibility of high-efficiency production.

In order to solve the technical problems, the technical scheme of the invention is as follows: the full-automatic packaging system comprises a human-computer operation interface, a master control system, a shell conveying device, a shell feeding device, a shell measuring device, an unqualified shell discharging device, a shell robot, a shell press-fitting positioning device, a liner conveying device, a liner grabbing device, a liner measuring device, a liner positioning device, an unqualified liner discharging device, a carrier conveying device, a carrier feeding device, a carrier measuring device, an unqualified carrier discharging device, a carrier robot, a wrapping device, a wrapping body transition device, a press-fitting device, a diameter reducing device, a finished product robot, a finished product marking device, a finished product measuring device, an unqualified finished product discharging device and a stacking robot;