CN102950510B - Checkout gear, flexible manufacturing system, flexible production line and detection method - Google Patents
Checkout gear, flexible manufacturing system, flexible production line and detection method Download PDFInfo
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- CN102950510B CN102950510B CN201210456852.2A CN201210456852A CN102950510B CN 102950510 B CN102950510 B CN 102950510B CN 201210456852 A CN201210456852 A CN 201210456852A CN 102950510 B CN102950510 B CN 102950510B
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Abstract
The invention provides a kind of checkout gear, for the flexible manufacturing system that aluminium alloy wheel hub of vehicle manufactures, wheel hub after flexible manufacturing system processing is detected, comprise: position degree detecting unit, for obtaining the real time position degree of the wheel hub machined, if real time position degree and predeterminated position degree match, then judge that the wheel hub machined meets the requirements, and by the robot in flexible manufacturing system, this wheel hub is placed in finished product material road, otherwise judge not meet, and by flexible manufacturing system this wheel hub processed again or be placed on waste product material road by robot.Correspondingly, present invention also offers a kind of flexible manufacturing system, a kind of flexible production line and a kind of detection method.By technical scheme of the present invention, manual operation can be reduced in the machining of automotive hub, improve accuracy of detection, also facilitate and in time defective work is processed accordingly, thus improve the stability of product and the utilization rate of equipment.
Description
Technical field
The present invention relates to machinery manufacturing technology field, in particular to a kind of checkout gear, a kind of flexible manufacturing system, a kind of flexible production line and a kind of detection method.
Background technology
At present, in the processing of the cylinder cap of automobile engine, cylinder body, the casing part such as gearbox body and clutch (Clutch) shell, the flexible production line be made up of high-speed machining center major part instead of transfer matic, high-speed machining center, has become the capital equipment of automobile engine casing part processing.
The main processing part of box parts is all made up of Grazing condition machining center, and several machining center forms a FMC (FMC).Charging roller before each FMC, after be blanking roller-way and measuring station.Coupled together by automatic roller-way or manipulator between each FMC, wherein also comprise necessary cleaning, grind, press-fit, leak test, on-line measurement, line external pelivimetry equipment and cutting fluid centralized processor etc.Auxiliary equipment generally adopts through type roller-way to carry material loading, by type identifier, selects corresponding station, leak test, tightens program.In FMC, whole line is provided with several manipulator, carries out loading and unloading by full-automatic mechanical hand.On the automatic roller-way of production line, be provided with product type automatic identification equipment, coupled together by bus between manipulator, roller-way, machining center, automatically controlled the uniformity of each several part by digital control system.Meanwhile, computer for controlling according to the processing situation of each lathe, can also select optimum loading and unloading order, and according to the scope set, is automatically put into measuring station by needing the workpiece of sampling observation.
But at present in the manufacture process of aluminium alloy wheel hub of vehicle, especially in some existing flexible manufacturing systems, also still there are some defects, in testing process such as the wheel hub after machining, at some as on the key parameters such as position degree, still need to be tested by manual type, make manually-operated labour intensity large, product stability can be caused poor, the utilization rate of equipment is not high simultaneously yet.
Therefore, a kind of new detection technique is needed, to solving the problems of the technologies described above.
Summary of the invention
The present invention, just based on the problems referred to above, proposes a kind of technology for aluminium alloy wheel hub of vehicle manufacture process, can realize the unattended of the processes such as manufacture, detection in mechanical processing process, improves the stability of product and the utilization rate of equipment.
In view of this, the present invention proposes a kind of checkout gear, for the flexible manufacturing system that aluminium alloy wheel hub of vehicle manufactures, wheel hub after described flexible manufacturing system processing is detected, comprise: position degree detecting unit, for obtaining the real time position degree of the wheel hub machined, if described real time position degree and predeterminated position degree match, the wheel hub machined described in then judging meets the requirements, and by the robot in described flexible manufacturing system, this wheel hub is placed in finished product material road, otherwise judge not meet, and by described flexible manufacturing system this wheel hub processed again or be placed on waste product material road by described robot.
In this technical scheme, can according to the certified products production requirement predeterminated position degree parameter of wheel hub, by carrying out Real-time Obtaining to hub positions degree, and it is mated with the position degree preset, thus judging that whether this wheel hub is qualified, certified products, defective work enter different material roads automatically, thus decrease manual operation, and the precision detected is higher, also facilitates and carry out accurately, timely processing to defective work.
In technique scheme, preferably, also comprise: offset distance detecting unit, in the process of processing described wheel hub at described flexible manufacturing system, obtain the real-time offset distance value of described wheel hub, and judge whether described real-time offset distance value and default offset distance value match; Rising head depth detection unit, in the process of processing described wheel hub at described flexible manufacturing system, obtains the real-time rising head degree of depth of described wheel hub, and judges whether the described real-time rising head degree of depth and the default rising head degree of depth match; Pore Diameter Detection unit, in the process of processing described wheel hub at described flexible manufacturing system, obtains the real-time center bore dia of described wheel hub, and judges whether described real-time center bore dia and default center bore dia match; Judged result analytic unit, when matching for being in the testing result of described offset distance detecting unit, described rising head depth detection unit and described Pore Diameter Detection unit, control described flexible manufacturing system to process further described wheel hub, otherwise by described flexible manufacturing system described wheel hub processed again or be placed on described waste product material road by described robot.
In this technical scheme, except the position degree processed wheel hub detects automatically, the center-hole diameter of the wheel hub offset distance value that the certified products can also presetting wheel hub should reach, the wheel hub rising head degree of depth, wheel hub, the center-hole diameter of the real-time wheel hub offset distance value obtained in process, in real time the wheel hub rising head degree of depth and real-time wheel hub is mated with its preset value, thus judge that whether above-mentioned several the parameters of wheel hub are qualified, next process is entered time qualified, defective, carry out reprocessing or scrapping.
In technique scheme, preferably, also comprise: automatic tool mends amending unit, for at described position degree detecting unit, described offset distance detecting unit, the testing result of described rising head depth detection unit and/or described Pore Diameter Detection unit is in unmatched situation, the automatic tool complement certificate of described flexible manufacturing system is revised, and when described testing result is coupling, if the real time data detected is more than or equal to preset difference value with corresponding preset data actual difference, then described automatic tool complement certificate is revised, described preset difference value is less than to control described actual difference.
In this technical scheme, due to the impact of the factors such as wearing and tearing, the loss of apparatus, the difference of blank part of cutter, even if when carrying out automatic tool benefit, still likely there are two kinds of situations: the first, the parameter of the wheel hub obtained is undesirable, and such as require that certain parameter is 1.00mm, allowable error scope is ± 0.05mm, the parameter of the wheel hub obtained is assumed to 1.06mm, then undesirable; The second, the parameter of the wheel hub obtained meets the requirements, but the position at the comparatively edge for error range, the parameter of the wheel hub such as obtained is 1.04mm, although be then in the error range of permission, but exist and exceed the risk of this scope, machined parameters may be caused man-hour undesirable adding next blank part.Therefore, for above-mentioned two situations, can to corresponding automatic tool complement according to carry out correction, the parameter of the wheel hub that the aft-loaded airfoil made obtains is as far as possible near canonical parameter (such as go up the 1.00mm in example, can control actual parameter to be in ± error range of 0.02mm is interior).
Present invention also offers a kind of flexible manufacturing system, comprise the checkout gear described in above-mentioned arbitrary technical scheme.
In technique scheme, preferably, also comprise: recognition device, for the information according to wheel hub to be produced, wheel hub blank part on described flexible manufacturing system Zhong Liao road is identified, thus captured the wheel hub blank part of the information corresponding to described wheel hub to be produced by described robot, to be processed it by described flexible manufacturing system.
In technique scheme, preferably, described recognition device comprises: image acquisition units, for carrying out IMAQ to described wheel hub blank part; Image analyzing unit, for carrying out discriminance analysis to the image collected, to judge whether it is required part.
In this technical scheme, the blank part of image recognition technology to wheel hub can be adopted to identify, specifically such as the image of Real-time Collection and pre-set image are compared, or after directly the image of Real-time Collection being processed, differentiate according to characteristic portion wherein.
Present invention also offers a kind of flexible production line, comprise the flexible manufacturing system in above-mentioned arbitrary technical scheme.In this technical scheme, flexible production line can comprise one or more above-mentioned flexible manufacturing system.
In technique scheme, preferably, also comprise: control terminal, bus is adopted to be connected with between described flexible manufacturing system, for according to the input operation received, generate corresponding input command, to control the production process of described flexible manufacturing system to wheel hub.
In this technical scheme, can be monitored production process by control terminal and control, and can obtain and record the information such as crudy and quantity, if when needing the part processing new varieties, as long as change its production schedule information, technical information and procedure, whole production system on request, automatically will complete new processing according to said process, operates convenient and swift.
In technique scheme, preferably, also comprise: security protection system, the edge for the appointed area in each described flexible manufacturing system arranges detecting sensor, and when the personnel of having detected enter this appointed area, control corresponding flexible manufacturing system and shut down.
In this technical scheme, be strayed in region corresponding to rotating range as robot to prevent user, particularly, such as grating inductor, infrared sensor, temperature sensor, press-type sensor can be adopted, thus detect the personnel whether existing and be strayed into this region, and when detecting, stop the work of flexible manufacturing system in time, ensure personal security.
Present invention also offers a kind of detection method, for the flexible production line that aluminium alloy wheel hub of vehicle manufactures, comprise: the real time position degree obtaining the wheel hub machined through described flexible production line, if described real time position degree and predeterminated position degree match, the wheel hub machined described in then judging meets the requirements and this wheel hub is placed in finished product material road, otherwise judges that not being inconsistent merging again processes this wheel hub or be placed on waste product material road.
In this technical scheme, can according to the certified products production requirement predeterminated position degree parameter of wheel hub, by carrying out Real-time Obtaining to hub positions degree, and it is mated with the position degree preset, thus judging that whether this wheel hub is qualified, certified products, defective work enter different material roads automatically, thus decrease manual operation, and the precision detected is higher, also facilitates and carry out accurately, timely processing to defective work.
In technique scheme, preferably, also comprise: in the process that described flexible production line is processed described wheel hub, obtain the real-time offset distance value of described wheel hub, in real time the rising head degree of depth and real-time center bore dia; If described real-time offset distance value and default offset distance value, the described real-time rising head degree of depth and the default rising head degree of depth, described real-time center bore dia and default center bore dia all match, then by described flexible production line, described wheel hub is processed further, otherwise described wheel hub is processed again or is placed on described waste product material road.
In this technical scheme, except the position degree processed wheel hub detects automatically, the center-hole diameter of the wheel hub offset distance value that the certified products can also presetting wheel hub should reach, the wheel hub rising head degree of depth, wheel hub, the center-hole diameter of the real-time wheel hub offset distance value obtained in process, in real time the wheel hub rising head degree of depth and real-time wheel hub is mated with its preset value, thus judge that whether above-mentioned several the parameters of wheel hub are qualified, next process is entered time qualified, defective, carry out reprocessing or scrapping.
In technique scheme, preferably, also comprise: under the testing result of the real-time offset distance value to described wheel hub, real-time the rising head degree of depth, real-time center bore dia and/or real time position degree is unmatched situation, the automatic tool complement certificate of described flexible production line is revised, and when described testing result is coupling, if the real time data detected is more than or equal to preset difference value with the actual difference of corresponding preset data, then described automatic tool complement certificate is revised, be less than described preset difference value to control described actual difference.
In this technical scheme, due to the impact of the factors such as wearing and tearing, the loss of apparatus, the difference of blank part of cutter, even if when carrying out automatic tool benefit, still likely there are two kinds of situations: the first, the parameter of the wheel hub obtained is undesirable, and such as require that certain parameter is 1.00mm, allowable error scope is ± 0.05mm, the parameter of the wheel hub obtained is assumed to 1.06mm, then undesirable; The second, the parameter of the wheel hub obtained meets the requirements, but the position at the comparatively edge for error range, the parameter of the wheel hub such as obtained is 1.04mm, although be then in the error range of permission, but exist and exceed the risk of this scope, machined parameters may be caused man-hour undesirable adding next blank part.Therefore, for above-mentioned two situations, can to corresponding automatic tool complement according to carry out correction, the parameter of the wheel hub that the aft-loaded airfoil made obtains is as far as possible near canonical parameter (such as go up the 1.00mm in example, can control actual parameter to be in ± error range of 0.02mm is interior).
By above technical scheme, the unattended of the processes such as manufacture, detection can be realized in the machining of aluminium alloy wheel hub of vehicle, improve the stability of product and the utilization rate of equipment.
Accompanying drawing explanation
Fig. 1 shows the block diagram of checkout gear according to an embodiment of the invention;
Fig. 2 shows the block diagram of flexible manufacturing system according to an embodiment of the invention;
Fig. 3 shows the block diagram of flexible production line according to an embodiment of the invention;
Fig. 4 shows the flow chart of detection method according to an embodiment of the invention;
Fig. 5 shows the schematic diagram of RS232 data wire wiring according to an embodiment of the invention;
Fig. 6 shows the interface schematic diagram that communications parameter is according to an embodiment of the invention arranged;
Fig. 7 shows the online schematic diagram of each parts in flexible manufacturing system according to an embodiment of the invention;
Fig. 8 shows the structural representation of 360 degree of turnover fixtures according to an embodiment of the invention;
Fig. 9 shows the layout of flexible production line according to an embodiment of the invention.
Detailed description of the invention
In order to more clearly understand above-mentioned purpose of the present invention, feature and advantage, below in conjunction with the drawings and specific embodiments, the present invention is further described in detail.It should be noted that, when not conflicting, the feature in the embodiment of the application and embodiment can combine mutually.
Set forth a lot of detail in the following description so that fully understand the present invention, but the present invention can also adopt other to be different from other modes described here and implement, and therefore, the present invention is not limited to the restriction of following public specific embodiment.
Fig. 1 shows the block diagram of checkout gear according to an embodiment of the invention.
As shown in Figure 1, checkout gear 100 according to an embodiment of the invention, for the flexible manufacturing system that aluminium alloy wheel hub of vehicle manufactures, wheel hub after described flexible manufacturing system processing is detected, comprise: position degree detecting unit 102, for obtaining the real time position degree of the wheel hub machined, if described real time position degree and predeterminated position degree match, the wheel hub machined described in then judging meets the requirements, and by the robot in described flexible manufacturing system, this wheel hub is placed in finished product material road, otherwise judge not meet, and by described flexible manufacturing system this wheel hub processed again or be placed on waste product material road by described robot.
In this technical scheme, can according to the certified products production requirement predeterminated position degree parameter of wheel hub, by carrying out Real-time Obtaining to hub positions degree, and it is mated with the position degree preset, thus judging that whether this wheel hub is qualified, certified products, defective work enter different material roads automatically, thus decrease manual operation, and the precision detected is higher, also facilitates and carry out accurately, timely processing to defective work.
In technique scheme, preferably, also comprise: offset distance detecting unit 104, in the process of processing described wheel hub at described flexible manufacturing system, obtain the real-time offset distance value of described wheel hub, and judge whether described real-time offset distance value and default offset distance value match; Rising head depth detection unit 106, in the process of processing described wheel hub at described flexible manufacturing system, obtains the real-time rising head degree of depth of described wheel hub, and judges whether the described real-time rising head degree of depth and the default rising head degree of depth match; Pore Diameter Detection unit 108, in the process of processing described wheel hub at described flexible manufacturing system, obtains the real-time center bore dia of described wheel hub, and judges whether described real-time center bore dia and default center bore dia match; Judged result analytic unit 110, when matching for being in the testing result of described offset distance detecting unit, described rising head depth detection unit and described Pore Diameter Detection unit, control described flexible manufacturing system to process further described wheel hub, otherwise by described flexible manufacturing system described wheel hub processed again or be placed on described waste product material road by described robot.
In this technical scheme, except the position degree processed wheel hub detects automatically, the center-hole diameter of the wheel hub offset distance value that the certified products can also presetting wheel hub should reach, the wheel hub rising head degree of depth, wheel hub, the center-hole diameter of the real-time wheel hub offset distance value obtained in process, in real time the wheel hub rising head degree of depth and real-time wheel hub is mated with its preset value, thus judge that whether above-mentioned several the parameters of wheel hub are qualified, next process is entered time qualified, defective, carry out reprocessing or scrapping.Like this, avoid the comparatively big error that manual detection causes, reduce the labour intensity of workman, improve the stability of production efficiency and product quality.
In technique scheme, preferably, also comprise: automatic tool mends amending unit 112, for at described position degree detecting unit 102, described offset distance detecting unit 104, the testing result of described rising head depth detection unit 106 and/or described Pore Diameter Detection unit 108 is in unmatched situation, the automatic tool complement certificate of described flexible manufacturing system is revised, and when described testing result is coupling, if the real time data detected is more than or equal to preset difference value with corresponding preset data actual difference, then described automatic tool complement certificate is revised, described preset difference value is less than to control described actual difference.
In this technical scheme, due to the impact of the factors such as wearing and tearing, the loss of apparatus, the difference of blank part of cutter, even if when carrying out automatic tool benefit, still likely there are two kinds of situations: the first, the parameter of the wheel hub obtained is undesirable, and such as require that certain parameter is 1.00mm, allowable error scope is ± 0.05mm, the parameter of the wheel hub obtained is assumed to 1.06mm, then undesirable; The second, the parameter of the wheel hub obtained meets the requirements, but the position at the comparatively edge for error range, the parameter of the wheel hub such as obtained is 1.04mm, although be then in the error range of permission, but exist and exceed the risk of this scope, machined parameters may be caused man-hour undesirable adding next blank part.Therefore, for above-mentioned two situations, can to corresponding automatic tool complement according to carry out correction, the parameter of the wheel hub that the aft-loaded airfoil made obtains is as far as possible near canonical parameter (such as go up the 1.00mm in example, can control actual parameter to be in ± error range of 0.02mm is interior).
Fig. 2 shows the block diagram of flexible manufacturing system according to an embodiment of the invention.
As shown in Figure 2, flexible manufacturing system 200 comprises checkout gear 100 as shown in Figure 1 according to an embodiment of the invention.
In technique scheme, preferably, also comprise: recognition device 204, for the information according to wheel hub to be produced, wheel hub blank part on described flexible manufacturing system 200 Zhong Liao road is identified, thus captured the wheel hub blank part of the information corresponding to described wheel hub to be produced by described robot, to be processed it by described flexible manufacturing system.
In technique scheme, preferably, described recognition device 204 comprises: image acquisition units 2042, for carrying out IMAQ to described wheel hub blank part; Image analyzing unit 2044, for carrying out discriminance analysis to the image collected, to judge whether it is required part.
In this technical scheme, the blank part of image recognition technology to wheel hub can be adopted to identify, specifically such as the image of Real-time Collection and pre-set image are compared, or after directly the image of Real-time Collection being processed, differentiate according to characteristic portion wherein.
Fig. 3 shows the block diagram of flexible production line according to an embodiment of the invention.
As shown in Figure 3, the flexible production line 300 of embodiments of the invention comprises flexible manufacturing system 200 as shown in Figure 2, and particularly, flexible production line 300 can comprise one or more flexible manufacturing system 200.
In technique scheme, preferably, flexible production line 300 also comprises: control terminal 302, bus is adopted to be connected with between described flexible manufacturing system 200, for the input operation that basis receives, generate corresponding input command, to control the production process of described flexible manufacturing system 200 pairs of wheel hubs.
In this technical scheme, can monitor by control terminal 302 pairs of production processes and control, and can obtain and record the information such as crudy and quantity, if when needing the part processing new varieties, as long as change its production schedule information, technical information and procedure, whole production system on request, automatically will complete new processing according to said process, operates convenient and swift.
In technique scheme, preferably, also comprise: security protection system 304, the edge for the appointed area in each described flexible manufacturing system 200 arranges detecting sensor, and when the personnel of having detected enter this appointed area, control corresponding flexible manufacturing system 200 and shut down.
In this technical scheme, be strayed in region corresponding to rotating range as robot to prevent user, particularly, such as grating inductor, infrared sensor, temperature sensor, press-type sensor can be adopted, thus detect the personnel whether existing and be strayed into this region, and when detecting, stop the work of flexible manufacturing system in time, ensure personal security.
Fig. 4 shows the flow chart of detection method according to an embodiment of the invention.
As shown in Figure 4, the detection method of embodiments of the invention, for the flexible production line that aluminium alloy wheel hub of vehicle manufactures, comprises step 402, obtains the real time position degree of the wheel hub machined through described flexible production line; Step 404, judges whether real time position degree matches with predeterminated position degree; Step 406, if described real time position degree and predeterminated position degree match, then the wheel hub machined described in judging meets the requirements and this wheel hub is placed in finished product material road, otherwise judges that not being inconsistent merging again processes this wheel hub or be placed on waste product material road.
In this technical scheme, a position degree can be preset according to the certified products production requirement of wheel hub, by carrying out Real-time Obtaining to hub positions, and it is mated with the position degree preset, thus judging that whether this wheel hub is qualified, certified products, defective work enter different material roads automatically, thus decrease manual operation, and the precision detected is higher, also facilitates and defective work is processed accordingly.
In technique scheme, preferably, also comprise: in the process that described flexible manufacturing system is processed described wheel hub, obtain the real-time offset distance value of described wheel hub, in real time the rising head degree of depth and real-time center bore dia; If described real-time offset distance value and default offset distance value, the described real-time rising head degree of depth and the default rising head degree of depth, described real-time center bore dia and default center bore dia all match, then by described flexible production line, described wheel hub is processed further, otherwise described wheel hub is processed again or is placed on described waste product material road.
In this technical scheme, the center-hole diameter of the wheel hub offset distance value that the certified products can presetting wheel hub should reach, the wheel hub rising head degree of depth, wheel hub, the center-hole diameter of the real-time wheel hub offset distance value obtained in process, in real time the wheel hub rising head degree of depth and real-time wheel hub is mated with its preset value, thus judge that whether above-mentioned several the parameters of wheel hub are qualified, next process is entered time qualified, defective, carry out reprocessing or scrapping.Like this, avoid the comparatively big error that manual detection causes, reduce the labour intensity of workman, improve the stability of production efficiency and product quality.
In technique scheme, preferably, also comprise: under the testing result of the real-time offset distance value to described wheel hub, real-time the rising head degree of depth, real-time center bore dia and/or real time position degree is unmatched situation, the automatic tool complement certificate of described flexible production line is revised, and when described testing result is coupling, if the real time data detected is more than or equal to preset difference value with the actual difference of corresponding preset data, then described automatic tool complement certificate is revised, be less than described preset difference value to control described actual difference.
In this technical scheme, due to the impact of the factors such as wearing and tearing, the loss of apparatus, the difference of blank part of cutter, even if when carrying out automatic tool benefit, still likely there are two kinds of situations: the first, the parameter of the wheel hub obtained is undesirable, and such as require that certain parameter is 1.00mm, allowable error scope is ± 0.05mm, the parameter of the wheel hub obtained is assumed to 1.06mm, then undesirable; The second, the parameter of the wheel hub obtained meets the requirements, but the position at the comparatively edge for error range, the parameter of the wheel hub such as obtained is 1.04mm, although be then in the error range of permission, but exist and exceed the risk of this scope, machined parameters may be caused man-hour undesirable adding next blank part.Therefore, for above-mentioned two situations, can to corresponding automatic tool complement according to carry out correction, the parameter of the wheel hub that the aft-loaded airfoil made obtains is as far as possible near canonical parameter (such as go up the 1.00mm in example, can control actual parameter to be in ± error range of 0.02mm is interior).
In the process realizing aluminium alloy wheel hub of vehicle manufacture, in order to realize the automatic production control for whole flow process, flexible production line 300 not only comprises the flexible manufacturing system 200 described in above each technical scheme, control terminal 302 and security protection system 304 etc., can also comprise automatic logistics system, automatic robot turns sequence system, automatic processing system etc.Below in conjunction with Fig. 5 to Fig. 9, each system is described in detail.
The course of work of the flexible production line 300 of aluminium alloy wheel hub of vehicle is as follows: first, according to the kind of producing and operation plan information command, data message is processed by its information system, is distributed, and according to given program, automatic logistics system is controlled, material storehouse will provide the wheel hub blank part of corresponding kind, now, automatic robot's industrial robot turned in sequence system automatically identifies and selects loaded and unloaded wheel hub, and is installed on corresponding lathe thereupon.Secondly, the wheel hub transported and procedure are encoded, identified by the procedure recognition device in automatic processing system, and therefrom select the cutting parameter etc. of its corresponding procedure, required cutter and each side, thus complete the automatic processing to wheel hub by automatic processing system.Finally, the control information converting process of being defeated by according to information system, is tested to the wheel hub of firm completion of processing by automatic checkout system (being equivalent to the checkout gear 100 shown in Fig. 1), to qualified finished work-piece by loading and unloading and transportation system's feeding warehouse for finished product.Meanwhile, by on-line communication the information transmission such as crudy and quantity to monitoring and tape deck.If when need process the part of new varieties, as long as change its production schedule information, technical information and procedure, whole flexible production line 300 on request, automatically will complete new processing according to said process.
One, mechanics of communication
Each system in flexible production line 300 or between device, needs the transmission realizing various information and data, therefore needs to develop corresponding on-line communication technology.
Particularly, PROFIBUS-DP can be adopted to realize the high-speed data transfer of field layer.Control system based on PROFIBUS-DP comprises master station and follow station, and wherein, main website reads the input information of slave station periodically and sends output information to slave station periodically.Bus cycle time must be shorter than main website (PLC) the program cycle time.Except the transmission of periodic user data, PROFIBUS-DP also provides the aperiodicity communication needed for intelligent equipment to carry out configuration.
Visit PROFIBUS-DP main website flush bonding module COM-C by program by dual port memories DPM, this dual port memories is divided into two parts, and agreement has nothing to do (loop-around data address space) relevant to agreement (acyclic data address spaces).Loop-around data to comprise between PROFIBUS-DP main website and slave station the Process image inputoutput data mutually exchanged, and acyclic packet contains and the data such as the protocol-dependent parameter of PROFIBUS-DP, message, order, state.
Process image exports data: host subscriber's program sends to the output data of PROFIBUS-DP slave station.
Process image input data: PROFIBUS-DP slave station sends to the output data of host subscriber's program.
Send mailbox: host subscriber's program sends to the acyclic message information of PROFIBUS-DP slave station, order, diagnosis, configuration file download etc.
Receive mailbox: PROFIBUS-DP slave station sends to the acyclic message information of host subscriber's program, and slave station warning, state, configuration file are uploaded.
Protocol parameter: PROFIBUS-DP protocol parameter information, baud rate, house dog time, circulation timei etc.
The fixation and recognition of wheel hub and PCD detect and pipeline carries out online signal control by definition I/O.
By mechanics of communication, can also fault diagnosis and alert process be carried out, specific as follows:
1, transmission technology: RS-485 twisted-pair feeder, paired cable or optical cable.Baud rate is bit/s from 9.6Kbit/s to 12M.As shown in Figure 5, its design parameter is arranged as shown in Figure 6 its data wire wiring diagram.
2, bus access: alternative space between each main website is MS master-slave transmission between main website and slave station.Support single main or multi-master system.In bus, maximum website (MS master-slave equipment) number is 126.
3, communicate: point-to-point (user data transmission) or broadcast (control instruction).Circulation MS master-slave user data transmits and acyclic master-master data transmission.
4, operational mode: run, remove, stop.
5, synchronous: control instruction allows input and output synchronous.Synchronous mode: export synchronous; Locking mode: input is synchronous.
6, function: the circulation user between DP main website and DP slave station has data transmission.The dynamically active of each DP slave station and can activating.The inspection of DP slave station configuration.Powerful diagnostic function, three grades of diagnosis diagnostic messages.What input or output is synchronous.Address is given to DP slave station by bus.Passage line is configured DP main website (DPM1), and the input and output data of every DP slave station are 246 bytes to the maximum.
7, reliability and protection mechanism: the transmission of all information is undertaken by Hamming distances HD=4.DP slave station band WatchDog Timer (Watchdog Timer).Access protection is carried out to the I/O of DP slave station.In DP main website, the user data of belt variable timer transmits and monitors.
8, device type: Equations of The Second Kind DP main website (DPM2) be can carry out programming, configuration, diagnosis equipment.First kind DP main website (DPM1) is Central Programmable controller.DP slave station is the driver, valve etc. of band binary value or analog input and output; Also can be intelligent slave station, namely slave station be supported able to programme, general intelligence slave station and another one PLC main frame simultaneously.
After setting up above-mentioned communication system based on PROFIBUS-DP, in a flexible manufacturing system 200 in the flexible production line 300 obtained, the schematic diagram of the annexation between each device as shown in Figure 7.
In the figure 7, based on PROFIBUS-DP, pipeline, positioning and recognizing device, robot, Digit Control Machine Tool 1, Digit Control Machine Tool 2, machining center, PCD checkout gear, ET checkout gear etc. are connected to central control cabinet respectively, at the PLC(Programmable LogicController of central control cabinet, programmable logic controller (PLC)) control under, realize the transmission of signal and the control to device, thus realize the manufacturing to wheel aluminium alloy wheel hub.Particularly, its processing sequence is order () → sequentially (two) → sequentially (three) → sequentially (four) → sequentially (five) → sequentially (six) → sequentially (seven) → sequentially (eight).
Two, automatic logistics system
In the automatic logistics system of flexible production line, comprise major ingredient road, charge channel, defective work material road, discharge channel.
(1) major ingredient road and charge channel
Major ingredient road comprises CCD and detects, and identifies the specification classification of workpiece, turns to charge channel after product identification to Auto-counting during charge channel, carries out radium-shine detection and complete angle locating after product to charge channel.When workpiece motion s is to manipulator material loading point, two, left and right V-block positions workpiece, make inner hole of workpiece and rotary core shaft below just concentric.Then jack-up cylinder is by rotary core shaft jack-up, and rotates.Above workpiece, radium-shine beginning carries out scanning recognition to workpiece with side, when determine that workpiece is qualified and be the specification classification of this unit processing time, then by determining the radium-shine of angle, its angle to be detected.After the angle of workpiece is also determined, rotary core shaft is stopped the rotation, and drives it to drop to material road by cylinder.Workpiece is caught away and is processed by robot of finally issuing an order.
(2) defective work material road
If it is not this unit processing specification that radium-shine sensor determines this workpiece, workpiece is placed on waste material road and transports (organize radium-shine sensor to determine its angle without the need to another, directly control rotary core shaft decline by misjudgment signal and workpiece is on material road) by robot of issuing an order.Ensure the process safety of lathe.If workpiece occurring the underproof words of workpiece size when detecting, also by robot, this changing of workpieces being transported to defective work material road and transporting.
(3) discharge channel
Discharge channel is that the qualified workpiece processed is transported to artificial blanking point, at discharge channel end, sensor is housed, and carries out detecting with or without material to workpiece, and when material road piled by workpiece, manipulator alarm has manually to be taken away workpiece.
Three, automatic robot turns sequence system
In artificial mechanism system of processing, product is all that a dead lift turns sequence in I sequence and II sequence process, and labor strength is large.In the technical program, by transposition machine device people and robot grab the robot formed turn sequence system replace a dead lift turn sequence.The positioning accuracy request of movement system to robot is higher, requires positioning precision≤0.3mm.Therefore first the technical program uses Robot Studio software to carry out analogue simulation to 6DOF articulated robot.By software emulation simulation, robot is positioned, located the rear I/O signal determining robot interior, the I/O signal of inside is defined.After completing the definition of I/O signal, the track route of robot is programmed.
Four, automatic tool mends correction Computerized Numerical Control processing technology
In the technical program, all important fitted position offset distances (ET), the trim rising head degree of depth, center-hole diameter (HUB), position degree are automatic detection, as detected defective again will processing product, now require that system of processing has automatic tool and mends correcting function.Automatic tool mends correcting function, for under offset distance detecting unit, rising head depth detection unit, Pore Diameter Detection unit and/or position degree detecting unit are unmatched situation to the testing result of above-mentioned fitted position respectively, the automatic tool complement certificate of flexible manufacturing system is revised, and when testing result is coupling, if the real time data detected is more than or equal to preset difference value with corresponding preset data actual difference, then automatic tool complement certificate is revised, be less than preset difference value to control actual difference.
Particularly, above two kinds are needed to carry out the situation that automatic tool mends correction, the first, assuming that the parameter of the wheel hub obtained is undesirable, such as require that certain parameter is 1.00mm, allowable error scope is ± 0.05mm, the parameter of the wheel hub obtained is assumed to 1.06mm, then undesirable; The second, the parameter of the wheel hub obtained meets the requirements, but the position at the comparatively edge for error range, the parameter of the wheel hub such as obtained is 1.04mm, although be then in the error range of permission, but exist and exceed the risk of this scope, machined parameters may be caused man-hour undesirable adding next blank part.Therefore, for above-mentioned two situations, can to corresponding automatic tool complement according to carry out correction, the parameter of the wheel hub that the aft-loaded airfoil made obtains is as far as possible near canonical parameter (such as go up the 1.00mm in example, can control actual parameter to be in ± error range of 0.02mm is interior).
The technical program has worked out according to PMC programming rule and corresponding address the PMC(Build-in PLC control that correcting function mended by the concrete cutter of Digit Control Machine Tool) program.Utilize PMC not only can the main shaft rotating of domination number controlled machine and start-stop, workpiece clamping with unclamp, the back work such as cutter changing, cutting fluid switch controls, and can also realize checkout equipment and the functions such as automatic transmission technology mended by Digit Control Machine Tool communication cutter.
Fig. 8 shows 360 degree of turnover fixture structure charts according to an embodiment of the invention.
Originally Cutter Body Processing with Machining Center need divide that PCD processes, valve port processing, the anti-Milling Machining of PCD and valve port process four procedures such as anti-milling and complete, and needs use four sleeve clamp simultaneously.As shown in Figure 7,360 ° of turnover fixtures that the present invention adopts can once complete Cutter Body Processing with Machining Center operation, reduce process time, save fixture cost of manufacture.These 360 ° of turnover fixture features are as follows: center swell determines the central point that core comes automatic capturing product and equipment, the depth of parallelism of product and body and machining center work top is reached minimal error by four equal height cushion blocks, wherein two equal height cushion blocks there are two oil cylinder press fixed product respectively, when programme-control is loosened, center swell part first reduces oil cylinder aside and loosens, take off workpiece, after loading onto new workpiece, programme-control clamps, after during core first expands and automatically divides, side oil cylinder is in clamping, starts automated machining of workpieces.
Five, security protection system
For ensureing the security of operation of transfer matic, design perimeter defense system outward at transfer matic.When the personnel of having detected enter this appointed area, control corresponding flexible manufacturing system and shut down, thus the personal safety of the personnel of guarantee.
Six, detection system
Detection system mainly comprises the parts such as IMAQ, image procossing, plane reference, simultaneously for user provides software operation interface and database management platform, and can monitor system mode in conjunction with external electrical signal.
Below in conjunction with Fig. 9, be described in detail based on flexible production line 300 of the present invention.
As shown in Figure 9, a whole set of flexible production line 300 is made up of 4 groups of relatively independent flexible manufacturing systems (shown in figure wherein 2 groups), and each flexible manufacturing system is made up of charge channel, product identification device, two numerically controlled lathes, machining center, manipulator, gripper of manipulator, two monitor stations, defective work material road, discharge channel, switch boards etc.4 groups of flexible manufacturing systems are formed by connecting by a transmission bus.
The production procedure of this flexible production line 300 is as follows: aluminum alloy hub blank is turned over by main conveyor line upper reaches, identify through product identification device, after enter secondary pipeline charge channel, product is transported to No. 1 lathe by manipulator after being located by angle and processes, air-blowing cleaning is carried out after No. 1 machine tooling, then be transported to No. 1 monitor station by manipulator and carry out ET, HUB and trim rising head depth detection, detect qualified after be transported to No. 2 lathes by manipulator and process, air-blowing cleaning is carried out after No. 2 machine toolings, then be transported to No. 3 lathes by manipulator to process, No. 3 lathes carry out the laggard promoting the circulation of qi blowing-out of completion of processing and wash, then be transported to No. 2 monitor stations by manipulator and carry out position degree detection, detect qualified after by the blanking of secondary pipeline discharge channel.
Based on technique scheme, the present invention utilizes the multiple new and high technology such as CAX and analogue system and design means, rapid Design and the large-scale automatic production line of development machines people, and digitized of going forward side by side is verified.Utilize Virtual Manufacture, by setting up " digital factory ", set up product manufacture procedural information platform, and with ERP informatization platform and product design information platform intergration, form the informatization platform of enterprise product manufacture process Life cycle.Carry out concurrent engineering, realize information sharing, improve production line flexibility and for quality control creation necessary condition.
In addition, the present invention also studies the sound Analysis of Stiffness Characteristics of numerical control equipment, complete machine dynamic analysis, structure, heat, is electrically coupled model and precision maintenance technology, performance optimization knowledge base; Machine system emulation and modal experimental technique; The modularity design technology of numerical control equipment, comprises Modularization modeling and optimisation technique, layout and combination technique, realizes rapid adjustment and the reconstruct of production line; Complete machine accuracy Design and trim designs.
Flexible production line processing aluminium alloy wheel hub of vehicle provided by the invention is adopted to realize:
(1) compared with artificial mechanism system of processing, production efficiency improves more than 30%;
(2) robot repetitive positioning accuracy≤0.3mm;
(3) converted products positional precision≤0.2mm;
(4) ellipse of converted products and bias≤0.3mm;
(5) checkout equipment ET accuracy of detection ± 0.1mm;
(6) the fastest beat 150s of production line;
(7) size range of converted products: 13 ~ 20 cun.
More than be described with reference to the accompanying drawings technical scheme of the present invention, consider in correlation technique, the machining carrying that wheel hub manufacturer adopts and loading and unloading work are all also that manually-operated labour intensity is large by manually completing, product stability can be caused poor, the utilization rate of equipment is not high simultaneously yet.Therefore, the invention provides a kind of flexible production line, a kind of flexible manufacturing system, a kind of detection system and a kind of detection method.By technical scheme of the present invention, can realize unattended in wheel machining, improve the stability of product and the utilization rate of equipment simultaneously.
In the present invention, term " first ", " second " only for describing object, and can not be interpreted as instruction or hint relative importance.Term " multiple " refers to two or more, unless otherwise clear and definite restriction.
The foregoing is only the preferred embodiments of the present invention, be not limited to the present invention, for a person skilled in the art, the present invention can have various modifications and variations.Within the spirit and principles in the present invention all, any amendment done, equivalent replacement, improvement etc., all should be included within protection scope of the present invention.
Claims (10)
1. a checkout gear, for the flexible manufacturing system that aluminium alloy wheel hub of vehicle manufactures, detects the wheel hub blank part after described flexible manufacturing system processing, it is characterized in that, comprising:
Position degree detecting unit, for obtaining the real time position degree of the wheel hub machined, if described real time position degree and predeterminated position degree match, the wheel hub machined described in then judging meets the requirements, and by the robot in described flexible manufacturing system, this wheel hub is placed in finished product material road, otherwise judge not meet, and by described flexible manufacturing system this wheel hub processed again or be placed on waste product material road by described robot; And
Multiple described checkout gear in described flexible manufacturing system adopts PROFIBUS-DP to realize the high-speed data transfer of field layer;
Offset distance detecting unit, in the process of processing described wheel hub at described flexible manufacturing system, obtains the real-time offset distance value of described wheel hub, and judges whether described real-time offset distance value and default offset distance value match;
Rising head depth detection unit, in the process of processing described wheel hub at described flexible manufacturing system, obtains the real-time rising head degree of depth of described wheel hub, and judges whether the described real-time rising head degree of depth and the default rising head degree of depth match;
Pore Diameter Detection unit, in the process of processing described wheel hub at described flexible manufacturing system, obtains the real-time center bore dia of described wheel hub, and judges whether described real-time center bore dia and default center bore dia match;
Judged result analytic unit, when matching for being in the testing result of described offset distance detecting unit, described rising head depth detection unit and described Pore Diameter Detection unit, control described flexible manufacturing system to process further described wheel hub, otherwise by described flexible manufacturing system described wheel hub processed again or be placed on described waste product material road by described robot.
2. checkout gear according to claim 1, is characterized in that, also comprises:
Automatic tool mends amending unit, under being unmatched situation for the testing result at described position degree detecting unit, described offset distance detecting unit, described rising head depth detection unit and/or described Pore Diameter Detection unit, the automatic tool complement certificate of described flexible manufacturing system is revised, and when described testing result is coupling, if the real time data detected is more than or equal to preset difference value with the actual difference of corresponding preset data, then described automatic tool complement certificate is revised, be less than described preset difference value to control described actual difference.
3. a flexible manufacturing system, is characterized in that, comprises checkout gear as claimed in claim 1 or 2.
4. flexible manufacturing system according to claim 3, is characterized in that, also comprises:
Recognition device, for the information according to wheel hub to be produced, wheel hub blank part on described flexible manufacturing system Zhong Liao road is identified, thus captured the wheel hub blank part of the information corresponding to described wheel hub to be produced by described robot, to be processed it by described flexible manufacturing system.
5. flexible manufacturing system according to claim 4, is characterized in that, described recognition device comprises:
Image acquisition units, for carrying out IMAQ to described wheel hub blank part;
Image analyzing unit, for carrying out discriminance analysis to the image collected, to judge whether it is required part.
6. a flexible production line, is characterized in that, comprises at least one flexible manufacturing system according to any one of claim 3 to 5.
7. flexible production line according to claim 6, is characterized in that, also comprises:
Control terminal, adopts bus to be connected with between described flexible manufacturing system, for according to the input operation received, generates corresponding input command, to control the production process of described flexible manufacturing system to wheel hub.
8. flexible production line according to claim 6, is characterized in that, also comprises:
Security protection system, the edge for the appointed area in each described flexible manufacturing system arranges detecting sensor, and when the personnel of having detected enter this appointed area, controls corresponding flexible manufacturing system and shut down.
9. a detection method, for the flexible manufacturing system such as according to any one of claim 3 to 5 and the flexible production line according to any one of claim 6 to 8, described flexible production line is used for aluminium alloy wheel hub of vehicle manufacture, it is characterized in that, comprising:
Obtain the real time position degree of the wheel hub machined through described flexible production line, if described real time position degree and predeterminated position degree match, the wheel hub machined described in then judging meets the requirements and this wheel hub is placed in finished product material road, otherwise judges that not being inconsistent merging again processes this wheel hub or be placed on waste product material road; And
Multiple described checkout gear in described flexible manufacturing system adopts PROFIBUS-DP to realize the high-speed data transfer of field layer;
In the process that described flexible manufacturing system is processed described wheel hub, obtain the real-time offset distance value of described wheel hub, in real time the rising head degree of depth and real-time center bore dia;
If described real-time offset distance value and default offset distance value, the described real-time rising head degree of depth and the default rising head degree of depth, described real-time center bore dia and default center bore dia all match, then by described flexible production line, described wheel hub is processed further, otherwise described wheel hub is processed again or is placed on described waste product material road.
10. detection method according to claim 9, is characterized in that, also comprises:
Under the testing result of the real-time offset distance value to described wheel hub, real-time the rising head degree of depth, real-time center bore dia and/or real time position degree is unmatched situation, the automatic tool complement certificate of described flexible manufacturing system is revised, and when described testing result is coupling, if the real time data detected is more than or equal to preset difference value with the actual difference of corresponding preset data, then described automatic tool complement certificate is revised, be less than described preset difference value to control described actual difference.
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