CN104190837A - Method and device for monitoring running state of cold header - Google Patents
Method and device for monitoring running state of cold header Download PDFInfo
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- CN104190837A CN104190837A CN201410353535.7A CN201410353535A CN104190837A CN 104190837 A CN104190837 A CN 104190837A CN 201410353535 A CN201410353535 A CN 201410353535A CN 104190837 A CN104190837 A CN 104190837A
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Abstract
The invention provides a method for monitoring a running state of a cold header. The method comprises the steps that main component parameters of the cold header in the normal state are collected, and a standard model of the cold header in the normal state is built; in the running process of the cold header, the main component parameters are collected, and a running model of the cold header is built; running model parameters of the cold header are compared with standard model parameters of the cold header, and whether the working state of the cold header is normal or not is judged; if slight errors exist, whether the error value of the errors has the tendency to continue to deteriorate is judged; if existence of tendency to continue to deteriorate is determined, alarm reminding faults and maintenance advices are set; if the running model parameters of the cold header seriously deviate from the standard model parameters, working of the cold header is stopped, and the alarm reminding faults and the maintenance advices are set. Due to adoption of the device, the technical requirement of a worker, the labor intensity and the rejection rate are greatly reduced. The unity of the quality of products is greatly improved, the service life of a mould is greatly prolonged, and the production efficiency is greatly improved.
Description
Technical field
The present invention relates to automation control area, be specifically related to automatic monitoring method and the device of cold headers.
Background technology
Cold headers are when upsetting product processed, and material, by drawing-inroller automatic feed, is coordinated and cut off material by scissors, cut-off-die, and chuck is delivered to relatively main nib concentric position by material, and flexible mould is pressed into main mould by material.By each station movable mold upsetting pressure moulding.Steps most in upsetting process processed are mechanical type, by the position of the mode solid mechanical structures such as screw mandrel, screw rod, nut.The stability of frame for movement position is the basis of cold headers operation.Such as the locus of flexible mould has directly determined life-span, the quality of product and the efficiency of production of mould.The locus of chuck feeding all need at every turn fixing a bit, wire rod could be stable enters mould.Perfect condition is each upsetting pressure, the relative position absolute stability of all mechanisms.But reality is that temperature fluctuation amplitude is large because the duty of cold headers is quite severe, the raw material tissue property of there are differences, there is the impact of vibratility in machine.And each mould at work, bear high-G always.Thereby make the frame for movement of cold headers in process of production, play pendulum always.
After at present equipment breaks down, can only rely on workman's experience, the motion state of detailed inspection all parts, carrys out the situation of failure judgement.And in the middle of machine running process, while often there will be the fortuitous events such as the skew of flexible mould position, feeding is not in place for chuck, equipment attrition gap overroof.While occurring as fortuitous event, can not overhaul machine in time, the lighter's mould damages, product rejection.Serious situation there will be the damage of machine bearing shell, crankshaft breakdown, the mould explosion serious production accident such as hurt sb.'s feelings.
Industry has also faced the situation that skilled worker leave no successor at present.This pensioner's retirement of older generation's technical staff, what this was changed one's profession changes one's profession.Younger generation's employee is again because of the oil pollution of cold headers, overweight working strength and complicated tune machine process, and other posies are engaged in selection.Cause the skilled worker of cold-heading industry seriously in short supply.
On domestic market, the cold headers checkout gear of several enterprise developments mainly concentrates on the detection after mould breakage, and these detectors can only carry out simple mould and damage judgement, or material has or not detection, can only after mould well damage, just can shut down.The critical defect that these detectors exist that precision is low in addition, function singleness, performance for stability are poor, cannot reduce personnel's workload.And the equipment of foreign brand name, function is with domestic identical, and just precision increases, but equipment price is expensive many, and the economic worth that this kind equipment produces is not high, and the general acceptance of industry is low.
Chinese invention patent publication number is the automatic detection device that the patent of invention of 103551478A discloses a kind of steel ball high-speed cold heading machine, this automatic detection device be the right side be fixed on PLC in cold headers frame, cold headers panel, module, fixedly formwork, fixedly ball mould, movable formwork, movable balls mould and pressure sensor form, pressure sensor is arranged in the hole of cold headers panel, and is connected with PLC on cold headers by wire.This scheme by detecting the size of impulsive force, detects the state of steel ball upsetting system when upsetting ball base processed.
This open source literature for be the detection method of shutting down after damaged, this detection method is by the detection of upset pressure value is realized to judgement.The fluctuation of force value is because mould is damaged or be short in needed material and cause material extruding not in place produced.This detection method can only be carried out mould and be collapsed mould, damaged rear shutdown.The problem of this kind of detection method existence is: the one, whether correctly can not detect mould installation site, and cannot improve die life; The 2nd, can not carry out device Errors state and give warning in advance, cannot reduce the outage probability of equipment; The 3rd, die location parameter can not be provided, thus the adjustment of machinery, or needing professional skilled worker to complete, operating efficiency is without change.And because this equipment exists serious design defect, reckon without the impact that in production process, thermal expansion phenomenon causes overall structure.So in normal productive process, thermal expansion phenomenon can have a strong impact on normal parameter value, allow detector precision reduce, and occur various unexpected situations.
Summary of the invention
For overcoming above problem, the present invention proposes a kind of monitoring method and monitoring device of cold headers running status.
The present invention is that the technical scheme that its technical problem of solution adopts is:
A monitoring method for cold headers running status, is characterized in that,
(1) main member parameter while gathering cold headers and normally work, comprises upper-lower position, position, left and right, the front dead-centre position of master slider of mould, sets up the master pattern of cold headers when normal work;
(2) the main member parameter while gathering cold headers operation, comprises upper-lower position, position, left and right, the front dead-centre position of master slider of mould, sets up the moving model of cold headers when work;
(3) cold headers moving model parameter and cold headers master pattern parameter are compared, judge whether cold headers moving model parameter exceeds master pattern parameter, and judge that it departs from master die offset and whether belongs to allowed band;
(4) if cold headers moving model parameter substantial deviation object module parameter stops cold headers work.
Further, main member parameter also comprises the monitoring front dead point of chuck feeding, the front dead point of material returned lever.
Further, main member parameter also comprises body temperature monitoring.
Further, also comprise the error message of show state in described step (4), how prompting solves fault.
A monitoring device for cold headers running status, comprises upper control machine, and master slider dead point displacement transducer 4 is set on the fuselage of described cold headers; At the top dead-centre installation position of movable moulding box 5 displacement sensor 71, at the bottom dead centre installation position of movable moulding box 5 displacement sensor 72; At movable moulding box 5 side direction installation position displacement sensors 8; At installation position, the front dead point of material returned lever displacement sensor, at installation position, the front dead point of chuck feeding displacement sensor, on master slider 2, be provided with temperature sensor; Displacement transducer, temperature sensor are connected with upper control machine input.
Further, described upper control machine is PLC, by PLC, carrys out collection analysis data, and the display interface show state parameter linking at PLC.
Further, described upper control machine adopts high-speed collection card to add PC pattern, by high-speed collection card collection analysis data, and in the display interface show state parameter of PC terminal.
The invention has the advantages that:
(1) method for monitoring operation states and the device of a kind of cold headers mechanism are provided, by various sophisticated sensors, carry out in process of production the operational factor of monitoring machinery, by upper control machine Treatment Analysis data, draw running status, carry out the variation of the various states of early warning, improve uniformity, the yield rate of product quality.
(2) this device, after there is cold headers fault, is pointed out malfunction, and fault solves reference scheme etc.The specification requirement of reduction to workman, labour intensity, improves production capacity efficiency.
(3) can be by the data that gather in mold exchange process; directly demonstrate the current relative position parameter of flexible mould; from optimum position, also need to regulate how many units, greatly reduce the technical difficulty of die adjustment, reduce downtime, the prolongation die life of equipment.
Accompanying drawing explanation
Fig. 1 installs main mould top view of the present invention afterwards;
Fig. 2 installs main mould perspective view of the present invention afterwards;
Fig. 3 is the front schematic view that the present invention proposes;
1: fuselage; 2: master slider; 3: master slider detects iron; 4: master slider dead point displacement transducer; 5: movable moulding box; 6: movable moulding box detects iron; 71: displacement transducer; 72: displacement transducer; 8: displacement transducer; 91: upper movable mold installation position; 92 times movable mold installation positions; 10: main mould.
The specific embodiment
For technological means, creation characteristic that the present invention is realized, reach object and effect is easy to understand, below in conjunction with diagram and specific embodiment, further set forth the present invention.
The present invention is by installation position displacement sensor on the fuselage of cold headers; monitor the relative distance of each mechanism and sensor; sensing data carries out acquisition process by host computer; compare with the master pattern parameter prestoring in database; to judge on cold headers, whether corresponding mechanism departs from, thereby judge whether cold headers need to shut down maintenance.
Applicant finds by research, make cold headers realize stable automatic monitoring, just must monitor the state of the main mechanical part of cold headers, mold component run location.And the state parameter that relates to the main mechanical part of cold headers, mold component run location has: the front position of mold movement, upper-lower position, position, left and right, the front dead point of chuck feeding, the front dead point of material returned lever.By installation of sensors is fixed on fuselage, the power that do not withstand shocks, difficult skew, position is relatively fixing, is difficult for changing.By sophisticated sensor is installed on fuselage, measure needed location parameter for this reason, analyze the running status of machine.
Specific implementation process of the present invention is as follows:
When collection cold headers are normally worked, the front position of mold movement, upper-lower position, position, left and right, the front dead point of chuck feeding, the front dead point of material returned lever parameter, set up the master pattern of cold headers when normal work.
As shown in Figure 1, 2, 3, to show the sensing station of installing on cold headers, in order reading conveniently, in Fig. 2, Fig. 3, not drawn cold headers airframe structure.Master slider dead point displacement transducer 4 is set on fuselage with the front dead-centre position of this Measurement die; For the upper-lower position that Measurement die moves, installation position displacement sensor 71 on the top dead-centre of movable moulding box 5, monitor the upper-lower position of lower movable mold; Installation position displacement sensor 72 on the bottom dead centre of movable moulding box 5, detects the upper-lower position of movable mold; For measuring position, left and right, at movable moulding box 5 side direction installation position displacement sensors 8; At the front dead point of chuck feeding, installation position, the front dead point of material returned lever displacement sensor.
As a further improvement on the present invention, the temperature sensor that also can arrange on master slider 2, revises the fuselage thermal expansion influence that the central variations in temperature of operation produces, and improves parameters precision.In lambda line alignment position, annulus inductive pick-up is set, detects raw-material having or not.
The data of the sensor collection are processed by upper control machine, for reducing costs, can make PLC as host computer, but because PLC picking rate is low, can not monitor detail data completely.As the more accurate data of needs monitoring, need to develop single-chip microcomputer as host computer, or coordinate high-speed collection card to realize with PC, comparatively speaking, single-chip microcomputer equipment cost is low, and development cost are high, and the construction cycle is long.PC equipment cost is high, and development cost are low, and the construction cycle is short.By upper control machine, carry out data processing relatively ripe in control field, omit the technology contents of this part for this reason.
Pass through the sensor, main member parameter while gathering cold headers operation, the front dead-centre position, upper-lower position, the position, left and right that comprise mold movement, the front dead point of chuck feeding, the front dead point of material returned lever, body temperature parameter, the moving model while setting up cold headers work;
When upper control machine is found the feeding dead-centre position parameter drift-out normal value of location status, chuck of flexible mould, send warning, seriously stop cold headers running.On host computer, be provided with display interface, by display interface, prompting in which operation goes wrong, and points out corresponding equipment to adjust scheme.
Upper movable mold upper-lower position locking nut in below abnormal by running status is loosening as embodiment, the work of how carrying out of this device is described: when cold headers are normally worked, when as loosening in the upper-lower position locking nut that occurs upper movable mold, when each upsetting pressure is produced, the parameter value of movable moulding box bottom dead centre displacement transducer 72 there will be fluctuation, if undulating value within allowed band, continues to produce.By the detail analysis to sensor parameters value, can recognize whether machine state has the sign that continues deterioration.As there is deterioration sign, just need to light early-warning lamp, and on display screen, demonstrate " fluctuation appears in upper movable mold dead point value ", and prompting: " need to check and confirm upper movable mold lock screw state ".Within if undulating value also belongs to the margin of tolerance, in the middle of prealarming process, machine can also continue to produce so.If workman is idle condition, can safeguard at once, if workman is at maintenance other machines, also can to this machine, safeguard again after a while.While safeguarding, workman can carry out corresponding machinery adjustment according to monitor early warning, repair prompt, location parameter, allows easily machine get back to normal operating conditions, proceeds to produce.If workman is in busy condition always, have no time this machine to safeguard.When system monitoring has surpassed the margin of tolerance to undulating value, autostop, warning.So processing mode had both guaranteed product quality, had guaranteed again the maximization of production efficiency.Because can get information about very much the state of every machine, make personnel's job placement more rationally, efficiently.And a lot of fatefulue mistakes can be found in advance, be revised in advance, greatly reduce working strength, improve equipment capacity, save mould consumption.
Below by cold headers flexible mould, change method of adjustment as embodiment, illustrate that native system is the tune machine difficulty that how to reduce workman.
The movable mold position of equipment is adjusted at present, relies on workman's experience and sensation completely, and technical difficulty is high, and adjusting machine time is long, and error rate is high.Native system is unified master slider position by master slider dead point displacement transducer 4 is set on master slider, has been equivalent to fix the front and back position of movable mold, and what measure is locus before and after mould; By the upper-lower position of movable mold on 72 sensor measurements corresponding to upper movable mold, by the upper-lower position of flexible mould under 71 sensor measurements corresponding to lower movable mold.Upper movable mold is run to operating position, by being arranged on the displacement transducer 8 of side direction, measure position, left and right; Lower movable mold is run to operating position, by displacement transducer 8, measure position, left and right; The front and back position that system moves the flexible mould collecting, upper-lower position, position, left and right are directly presented on display screen, allow workman can get information about very much the reduced parameter when front mold physical location and mould optimum position, by mould physical location and optimum position are compared, thus the position that judges whether to need to continue adjustment mould.Such design, has got rid of workman's sense organ difference, technological disparity, can guarantee to greatest extent the uniformity of all products, improves greatly workman's operating efficiency.Such design reduces the technical difficulty of die adjustment greatly, reduces the downtime of equipment.And the current smart wearing and tearing situation major part that is washed into pattern aborning shows as asymmetrical wear, and (damaging phenomenon is that essence is rushed monolateral damage, opposite side normal condition.This be because mould while installing movable mold eccentric, cause mould bear pressure unbalanced due to).By high-precision mould, proofread and correct, can very effective prolongation die life.
More than show and described basic principle of the present invention, principal character and advantage of the present invention.The technical staff of the industry should understand; the present invention is not restricted to the described embodiments; that in above-described embodiment and description, describes just illustrates principle of the present invention; the present invention also has various changes and modifications without departing from the spirit and scope of the present invention, and these changes and improvements all fall in the claimed scope of the invention.
Claims (7)
1. a monitoring method for cold headers running status, is characterized in that,
(1) main member parameter while gathering cold headers and normally work, comprises upper-lower position, position, left and right, the front dead-centre position of master slider of mould, sets up the master pattern of cold headers when normal work;
(2) the main member parameter while gathering cold headers operation, comprises upper-lower position, position, left and right, the front dead-centre position of master slider of mould, sets up the moving model of cold headers when work;
(3) cold headers moving model parameter and cold headers master pattern parameter are compared, judge whether cold headers moving model parameter exceeds master pattern parameter, and judge that it departs from master die offset and whether belongs in allowed band;
(4) if cold headers moving model parameter substantial deviation master pattern parameter stops cold headers work.
2. the monitoring method of a kind of cold headers running status according to claim 1, is characterized in that, main member parameter also comprises the monitoring front dead point of chuck feeding, the front dead point of material returned lever.
3. the monitoring method of a kind of cold headers running status according to claim 1, is characterized in that, main member parameter also comprises body temperature monitoring.
4. the monitoring method of a kind of cold headers running status according to claim 1, is characterized in that, also comprises the error message of show state in described step (4), and how prompting solves fault.
5. a monitoring device for cold headers running status, comprises upper control machine, it is characterized in that, master slider dead point displacement transducer (4) is set on the fuselage of described cold headers; At the top dead-centre installation position of movable moulding box (5) displacement sensor (71), at the bottom dead centre installation position of movable moulding box (5) displacement sensor (72); At movable moulding box (5) side direction installation position displacement sensor (8); At installation position, the front dead point of material returned lever displacement sensor, at installation position, the front dead point of chuck feeding displacement sensor, master slider is provided with temperature sensor on (2); Displacement transducer, temperature sensor are connected with upper control machine input.
6. the monitoring device of a kind of cold headers running status according to claim 5, is characterized in that, described upper control machine is PLC, by PLC, carrys out collection analysis data, and the display interface show state parameter linking at PLC.
7. the monitoring device of a kind of cold headers running status according to claim 5, it is characterized in that, described upper control machine adopts high-speed collection card to add PC terminal, by high-speed collection card image data, and process in PC terminal analysis, in display interface show state parameter.
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Cited By (8)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN104942196A (en) * | 2015-07-01 | 2015-09-30 | 吉林圆方机械集团有限公司 | Forging and pressing equipment |
| CN108982007A (en) * | 2018-09-27 | 2018-12-11 | 江苏天毅冷镦股份有限公司 | Cold headers pressure sensor calibrating apparatus |
| CN110553686A (en) * | 2019-10-12 | 2019-12-10 | 重庆四标精密零部件制造有限公司 | Cold header running state monitoring system |
| CN110744000A (en) * | 2019-09-06 | 2020-02-04 | 安徽巨一自动化装备有限公司 | Method for monitoring service life of self-punching riveting die of steel-aluminum hybrid vehicle body based on riveting curve |
| CN111759216A (en) * | 2020-03-19 | 2020-10-13 | 广东蓝水花智能电子有限公司 | Automatic door opening and closing control method |
| CN112394680A (en) * | 2020-11-13 | 2021-02-23 | 江苏新泰隆管件有限公司 | Online monitoring system and method for running state of hot die forging press |
| CN112947334A (en) * | 2021-02-05 | 2021-06-11 | 深圳市天圳自动化技术有限公司 | Regenerated aluminum production data tracing and benchmarking system and method based on big data |
| CN113263125A (en) * | 2018-01-12 | 2021-08-17 | 宁波会德丰铜业有限公司 | Forging and pressing production system and management method thereof |
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| CN110744000A (en) * | 2019-09-06 | 2020-02-04 | 安徽巨一自动化装备有限公司 | Method for monitoring service life of self-punching riveting die of steel-aluminum hybrid vehicle body based on riveting curve |
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| CN111759216A (en) * | 2020-03-19 | 2020-10-13 | 广东蓝水花智能电子有限公司 | Automatic door opening and closing control method |
| CN112394680A (en) * | 2020-11-13 | 2021-02-23 | 江苏新泰隆管件有限公司 | Online monitoring system and method for running state of hot die forging press |
| CN112394680B (en) * | 2020-11-13 | 2021-09-28 | 江苏新泰隆管件有限公司 | Online monitoring system and method for running state of hot die forging press |
| CN112947334A (en) * | 2021-02-05 | 2021-06-11 | 深圳市天圳自动化技术有限公司 | Regenerated aluminum production data tracing and benchmarking system and method based on big data |
| CN112947334B (en) * | 2021-02-05 | 2022-08-05 | 深圳市天圳自动化技术有限公司 | Regenerated aluminum production data tracing and benchmarking system and method based on big data |
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