CN114769516A - Automatic machining process of new energy automobile brake calipers - Google Patents
Automatic machining process of new energy automobile brake calipers Download PDFInfo
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- CN114769516A CN114769516A CN202210542130.2A CN202210542130A CN114769516A CN 114769516 A CN114769516 A CN 114769516A CN 202210542130 A CN202210542130 A CN 202210542130A CN 114769516 A CN114769516 A CN 114769516A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/10—Cores; Manufacture or installation of cores
- B22C9/108—Installation of cores
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/22—Moulds for peculiarly-shaped castings
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D2/00—Arrangement of indicating or measuring devices, e.g. for temperature or viscosity of the fused mass
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D29/00—Removing castings from moulds, not restricted to casting processes covered by a single main group; Removing cores; Handling ingots
- B22D29/001—Removing cores
- B22D29/005—Removing cores by vibrating or hammering
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D29/00—Removing castings from moulds, not restricted to casting processes covered by a single main group; Removing cores; Handling ingots
- B22D29/04—Handling or stripping castings or ingots
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D30/00—Cooling castings, not restricted to casting processes covered by a single main group
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D31/00—Cutting-off surplus material, e.g. gates; Cleaning and working on castings
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D41/00—Casting melt-holding vessels, e.g. ladles, tundishes, cups or the like
- B22D41/12—Travelling ladles or similar containers; Cars for ladles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
Abstract
The invention discloses an automatic processing technology of new energy automobile brake calipers, and relates to the technical field of automobile part processing. The automatic processing technology comprises automatic core setting, pouring, workpiece taking, cooling, defect detection, doffing, cutting, deburring and workpiece setting output, wherein automatic core setting is completed through a sand core machine robot, liquid taking and pouring are completed through a pouring robot, and clamping and transferring in the processes of cooling, defect detection, doffing, cutting, deburring and workpiece setting output are completed through a post-processing robot; the pouring step is provided with a seven-shaft pouring arm and a liquid taking and pouring mechanism, so that the liquid taking angle can be adjusted in time or the molten aluminum alloy can be supplemented; in the doffing step, high-frequency hammering is matched with swing oscillation, so that the sand core is quickly separated, cracked and scattered from the surface of the cooling semi-finished product, the sand core is not easy to remain on the surface of the cooling semi-finished product, and the sand core removal rate reaches over 95 percent; the automatic processing technology is high in processing efficiency and sand core removal rate, and the quality of finished products is guaranteed.
Description
Technical Field
The invention relates to the technical field of automobile part processing, in particular to an automatic processing technology of new energy automobile brake calipers.
Background
The automobile brake caliper is a casting with compactness requirement, cannot have the defect problems of shrinkage cavity, shrinkage porosity and the like in practical application, all influencing factors are comprehensively analyzed on the basis of connection with reality, the casting process is optimized, the automobile brake caliper is efficiently cast, the tensile strength, the yield strength, the elongation and the like are controlled within the specified range, the function of the brake caliper is enabled to be exerted to the maximum, and the safety, the reliability and the economy of automobile operation are improved. The improvement of the casting process of the automobile brake caliper can be started from two major layers of a pouring system and alloy components, the casting process is further optimized on the basis of analyzing the improved result, and the function of the brake caliper in the operation of an automobile is ensured to be played to the maximum extent.
The prior art (CN112719818A) discloses a processing method of an automobile brake caliper, which relates to the technical field of automobile brake caliper manufacturing and comprises the following steps: s1, processing and selecting materials; s2, die casting and forming; s3, positioning and drilling; s4, polishing and grinding; s5, paint spraying: and selecting proper paint, and spraying the paint by using a spraying device to ensure that the paint on the surface of the caliper blank is uniformly distributed. According to the automobile brake caliper, the carbon steel is selected for processing the caliper, the hardness of the whole structure of the caliper can be guaranteed, the caliper can be used as a brake for a long time, the caliper cannot be worn out, the processing efficiency of the caliper can be improved through integrated die-casting molding of the high-temperature steel, the caliper is suitable for batch production of the caliper, meanwhile, the caliper has a high corrosion-resistant effect due to spraying processing of the processed caliper, the problem that the caliper is exposed and rusted is avoided, and the processing practicability of the automobile brake caliper is greatly improved. The processing technology of the new energy automobile brake caliper made of the aluminum alloy material in the prior art has the following technical problems: automated processing is not possible and the sand core removal rate needs to be increased to ensure the quality of the finished product.
A solution is now proposed to address the technical drawback in this respect.
Disclosure of Invention
The invention aims to provide an automatic processing technology of new energy automobile brake calipers, which is used for solving the technical problems that automatic processing cannot be carried out and the sand core removal rate needs to be improved to ensure the quality of finished products in the prior art.
The purpose of the invention can be realized by the following technical scheme:
the automatic processing technology of the new energy automobile brake caliper comprises the following steps:
s1, automatic core setting: taking off the sand core of the brake caliper of the new energy automobile from the double-layer sand core table through a sand core placing robot and placing the sand core on a sand core mould of the gravity casting machine;
s2, pouring: a pouring robot provided with a seven-axis pouring arm and a liquid taking and pouring mechanism scoops the aluminum alloy melt from the crucible holding furnace, and pours the aluminum alloy melt into a sand core mold of a gravity casting machine to obtain a poured semi-finished product;
s3, taking a workpiece: taking down the casting semi-finished product by the taking-out fixture and hanging the casting semi-finished product on an air cooling frame;
s4, cooling: an air cooling frame provided with an axial flow fan is used for cooling the poured semi-finished product to room temperature to obtain a cooled semi-finished product; a sand core collecting box is arranged below the air cooling frame;
s5, defect detection: the post-processing robot takes the cooled semi-finished product down from the air cooling frame, places the cooled semi-finished product on a sampling inspection table, adopts CCD visual inspection to detect whether the cooled semi-finished product has defects, and screens out qualified cooled semi-finished products;
s6, doffing: the post-processing robot places the qualified cooled semi-finished product on a sand beating machine, separates the cooled semi-finished product from the sand core on the surface in a high-frequency hammering and swinging oscillation mode, cracks the cooled semi-finished product into blocks, and eliminates the blocks to obtain a doffed semi-finished product;
s7, cutting: cutting and removing a pouring gate of the doffing semi-finished product by adopting a double-station automatic cutting machine to obtain a cut semi-finished product;
s8, deburring: deburring the parting line of the cut semi-finished product by adopting a deburring robot provided with a deburring tool to obtain a finished product of the new energy automobile brake caliper;
s9, outputting the next piece: and the post-processing robot places the new energy automobile brake caliper finished product on a plate chain conveying line to finish unloading.
Furthermore, the specification and model of the sand core placing robot is R-2000 IC/165; the double-layer sand core platform comprises a double-layer shuttle platform, eight-mold sand cores are placed on each layer of shuttle platform, and the new energy automobile brake calipers are double-cylinder calipers.
Furthermore, the specification and model of the pouring robot is R-2000 IC/165; two sand core molds are arranged in the gravity casting machine, the force of a mold opening oil cylinder is 44kN, the force of a mold closing oil cylinder is 47kN, and the cycle beat of each gravity casting machine is less than or equal to 256 s/mold.
Further, the compressed air pressure at the time of high-frequency hammering was 0.6MPa, and the consumption was 18000L/h.
Furthermore, compressed air is introduced into the double-station automatic cutting machine, the pressure of the compressed air is 0.6MPa, the consumption is 100L/h, and the cutting precision is +/-0.5 mm.
Furthermore, the deburring residual quantity of the parting line is 0-0.4 mm, and the deburring takt is not more than 43 s/piece.
Furthermore, the liquid taking and pouring mechanism comprises an assembling head, a sampling box and a sampling cover, wherein the assembling head is fixedly arranged at the top of the sampling box, the sampling cover is arranged outside the sampling box in a covered mode and is fastened through bolts, a pouring ladle mechanism is rotatably connected to the position, close to the bottom, of the sampling box, and two detecting tubes extending out of the bottom of the sampling box are arranged in an inner cavity of the sampling box;
the pouring ladle mechanism comprises a double-shaft motor, a sleeve, a rotating shaft and a stainless steel pouring ladle, the double-shaft motor is arranged in the inner cavity of the sampling box and close to the bottom, a motor shaft of the double-shaft motor extends towards two sides and is connected with the sleeve through a coupler, and the outer end of the sleeve is fixedly connected with the stainless steel pouring ladle through the rotating shaft; one end of the rotating shaft extends into the inner cavity of the sleeve and is connected with the inner wall of the sleeve through a compression spring; limiting plates for limiting the rotation angle of the rotating shaft are fixed on the upper side and the lower side of the rotating shaft;
the position detection sensor is installed to the inner chamber of search tube, and the top of two search tubes is connected with the diaphragm, and the top of sampling box is fixed with telescopic cylinder, and telescopic cylinder's piston rod passes through fixed block and diaphragm fixed connection, is equipped with in the sampling box and supplies the gliding spout of search tube.
Furthermore, the sand hammering machine comprises a rack, a hammering box and a waste sand collecting chamber, wherein the hammering box and the waste sand collecting chamber are respectively arranged at the top and the bottom of the rack, a sound insulation chamber is arranged inside the hammering box, and a sound insulation door is assembled outside the sound insulation chamber; a high-frequency hammering mechanism and an oscillation positioning mechanism are arranged in the hammering box.
Furthermore, the oscillation positioning mechanism comprises a bevel gear speed reducer, a positioning frame and a driving shaft, the bevel gear speed reducer is fixed to the top of one side of the hammering box, an output shaft of the bevel gear speed reducer is assembled with the driving shaft extending into the sound insulation chamber, a driving gear is fixed to the end of the driving shaft, a driven gear is meshed below the driving gear, and a driven shaft extending to the inner wall of the hammering box penetrates through the axis of the driven gear; a first auxiliary shaft penetrating through the inner wall of the hammering box is arranged on the other side of the hammering box, and a first auxiliary gear is fixedly arranged at the end part of the first auxiliary shaft, which is positioned in the sound insulation chamber; a second auxiliary gear is meshed below the first auxiliary gear, a second auxiliary shaft extending to the inner wall of the hammering box penetrates through the axis of the second auxiliary gear, and limit bearings are arranged at the contact positions of the peripheries of the driven shaft and the second auxiliary shaft and the inner wall of the hammering box; the end parts of the driven shaft and the second auxiliary shaft, which are close to the soundproof room, are connected with V-shaped support frames, and positioning frames are connected between the bottoms of the two support frames.
Furthermore, high-speed blowers are arranged at the tops of two sides of the rack and connected with air supply pipes extending to the upper part of the outer side of the positioning frame; the periphery of the hammering box adopts a steel structure frame, sound absorption rock wool with the thickness of more than or equal to 80mm is filled in the periphery of the sound insulation chamber, and a plurality of layers of sand guide plates are arranged below the inner cavity of the frame, which is positioned below the sound insulation chamber.
The invention has the following beneficial effects:
1. according to the automatic processing technology of the new energy automobile brake caliper, automatic core setting is completed through a sand core releasing robot, liquid taking and pouring are completed through a pouring robot, and clamping and transferring in the processes of cooling, defect detection, doffing, cutting, deburring and workpiece discharging are completed through a post-processing robot; in the pouring step, a seven-shaft pouring arm and a liquid taking and pouring mechanism are arranged, so that the liquid taking angle can be adjusted in time or the aluminum alloy melt can be supplemented; in the doffing step, high-frequency hammering is matched with swing oscillation, so that the sand core is quickly separated, cracked and scattered from the surface of the cooling semi-finished product, the sand core is not easy to remain on the surface of the cooling semi-finished product, and the sand core removal rate reaches over 95 percent; the automatic processing technology has high processing efficiency and high sand core removal rate, and ensures the quality of finished products.
2. The liquid taking and pouring mechanism controls the synchronous liquid taking of the two stainless steel pouring ladles through the double-shaft motor and the rotating shaft, and the liquid level position of the aluminum alloy molten liquid is matched for detection by moving the position of the probe tube, so that the liquid taking angle can be adjusted in time or the aluminum alloy molten liquid can be supplemented.
3. The sand beating machine enables the supporting frame and the positioning frame to form regular swing oscillation by controlling the forward and reverse rotation of the bevel gear reducer, and promotes the separation and removal of sand cores; the driven shaft, the first auxiliary shaft and the second auxiliary shaft respectively play a role in positioning and supporting the driven gear, the first auxiliary gear and the second auxiliary gear, and the gear transmission keeps the stability and regularity of the swing oscillation of the positioning frame; high-speed wind power generated by the high-speed blower is blown into the positioning frame and the brake calipers through the blast pipe to cool the semi-finished product, so that the separated sand cores enter the waste sand collecting chamber through the sand guide plate, and the sand cores are prevented from remaining on the positioning frame.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below, it is obvious that the drawings in the following description are only some embodiments of the present invention, and for those skilled in the art, other drawings can be obtained according to the drawings without creative efforts.
FIG. 1 is a flow chart of an automatic processing process of the new energy automobile brake caliper;
FIG. 2 is a front view of the tapping and pouring mechanism of the present invention;
FIG. 3 is a schematic structural view of the liquid-extracting and pouring mechanism of the present invention with the sampling cover removed;
FIG. 4 is an enlarged view of a portion of FIG. 3 at A;
FIG. 5 is a schematic view showing the combination of the sleeve, the rotating shaft, the stainless steel ladle and the limiting plate according to the present invention;
FIG. 6 is a front view of the sander of the present invention;
FIG. 7 is a schematic structural view of the sand blasting machine of the present invention with the soundproof door and the casing of the hammering box removed;
FIG. 8 is an enlarged view of a portion of FIG. 7 at B;
FIG. 9 is a side view of the engagement mechanism of the first auxiliary gear, the second auxiliary gear, the support bracket and the positioning bracket of the present invention;
fig. 10 is a schematic structural view of the high-frequency hammer mechanism of the present invention.
Reference numerals: 1. assembling the head; 2. a sampling box; 3. a sampling cover; 4. a probe tube; 5. a double-shaft motor; 6. a sleeve; 7. a rotating shaft; 8. stainless steel casting ladle; 9. a coupling; 10. a limiting plate; 11. a position detection sensor; 12. a transverse plate; 13. a telescopic cylinder; 14. a fixed block; 15. a chute; 16. a bolt; 17. a frame; 18. a hammering box; 19. a waste sand collection chamber; 20. a sound-proof chamber; 21. a soundproof door; 22. a bevel gear reducer; 23. a positioning frame; 24. a drive shaft; 25. a driving gear; 26. a driven gear; 27. a driven shaft; 28. a first auxiliary shaft; 29. a first auxiliary gear; 30. a second auxiliary gear; 31. a second auxiliary shaft; 32. a support frame; 33. a high speed blower; 34. an air supply pipe; 35. sound-absorbing rock wool; 36. a sand guide plate; 37. a high-frequency air hammer; 38. a mounting cavity; 39. a hammer head; 40. an air inlet head; 41. an air inlet pipe; 42. shock-absorbing rubber; 43. mounting a plate; 44. a hydraulic cylinder; 45. a limiting bearing; 91. compressing the spring.
Detailed Description
The technical solutions of the present invention will be described clearly and completely with reference to the following embodiments, and it should be understood that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
Example 1
As shown in fig. 1, the present embodiment provides an automatic processing technology of a new energy automobile brake caliper, including the following steps:
s1, automatic core setting: taking off the sand core of the new energy automobile brake caliper from the double-layer sand core table through a sand core placing robot, and placing the sand core on a sand core mold of a gravity casting machine; wherein the specification model of the sand core releasing robot is R-2000 IC/165; the double-layer sand core table comprises double-layer shuttle tables, eight-mold sand cores are placed in each layer of shuttle table, and the new energy automobile brake calipers are double-cylinder calipers;
s2, casting: scooping the aluminum alloy melt from the crucible holding furnace by adopting a pouring robot provided with a seven-axis pouring arm and a liquid taking and pouring mechanism, and pouring the aluminum alloy melt into a sand core mold of a gravity casting machine to obtain a poured semi-finished product; wherein the specification and model of the pouring robot is R-2000 IC/165; two sand core molds are arranged in the gravity casting machine, the force of a mold opening oil cylinder is 44kN, the force of a mold closing oil cylinder is 47kN, and the circulating beat of each gravity casting machine is less than or equal to 256 s/mold;
s3, taking a piece: taking down the casting semi-finished product by the taking-out clamp and hanging the casting semi-finished product on an air cooling frame;
s4, cooling: an air cooling frame provided with an axial flow fan is used for cooling the poured semi-finished product to room temperature to obtain a cooled semi-finished product; wherein a sand core collecting box is arranged below the air cooling frame;
s5, defect detection: the post-processing robot takes the cooled semi-finished product down from the air cooling frame, places the cooled semi-finished product on a sampling inspection table, adopts CCD visual inspection to detect whether the cooled semi-finished product has defects, and screens out qualified cooled semi-finished products; wherein the specification and model of the post-processing robot is R-2000 IC/165;
s6, doffing: the post-processing robot places the qualified cooled semi-finished product on a sand beating machine, separates the cooled semi-finished product from the sand core on the surface in a high-frequency hammering and swinging oscillation mode, cracks the cooled semi-finished product into blocks, and eliminates the blocks to obtain a doffed semi-finished product; wherein the compressed air pressure is 0.6MPa during high-frequency hammering, and the consumption is 18000L/h;
s7, cutting: cutting and removing a pouring gate of the doffing semi-finished product by adopting a double-station automatic cutting machine to obtain a cut semi-finished product; compressed air is introduced into the double-station automatic cutting machine, the pressure of the compressed air is 0.6MPa, the consumption is 100L/h, and the cutting precision is +/-0.5 mm;
s8, deburring: deburring the parting line of the cut semi-finished product by adopting a deburring robot with a deburring tool to obtain a finished product of the brake caliper of the new energy automobile; the deburring residual quantity of the parting line is 0-0.4 mm, and the deburring beat is less than or equal to 43s per piece;
s9, outputting the next piece: the post-processing robot places the finished brake calipers of the new energy automobile on a plate chain conveying line to finish unloading; wherein, four new energy automobile braking calliper finished products are placed to the width direction of plate link chain transfer chain.
The automatic machining process of the new energy automobile brake caliper comprises the steps of automatic core setting, pouring, piece taking, cooling, defect detection, doffing, cutting, deburring and piece setting output, wherein automatic core setting is completed through a sand core placing robot, liquid taking and pouring are completed through a pouring robot, and clamping and transferring in the processes of cooling, defect detection, doffing, cutting, deburring and piece setting output are completed through a post-processing robot; the pouring step is provided with a seven-shaft pouring arm and a liquid taking and pouring mechanism, so that the liquid taking angle can be adjusted in time or the molten aluminum alloy can be supplemented; in the doffing step, high-frequency hammering is matched with swing oscillation, so that the surface of the sand core and the surface of the cooled semi-finished product are quickly separated, cracked and scattered, the sand core is not easy to remain on the surface of the cooled semi-finished product, and the sand core removal rate reaches over 95 percent. The automatic processing technology has high processing efficiency and high sand core removal rate, and ensures the quality of finished products.
Example 2
As shown in fig. 2-5, this embodiment provides a get liquid pouring mechanism for carry out the level detection of aluminum alloy melt and get liquid pouring after the seven pouring arms of pouring robot assemble, including assembly head 1, sampling box 2 and sample lid 3, assembly head 1 is fixed and is located the top of sampling box 2, and sampling lid 3 covers the outside of locating sampling box 2 and fastens through bolt 16, and sampling box 2 is close to bottom department and rotates and is connected with the ladle mechanism, and the inner chamber of sampling box 2 is equipped with two exploring tubes 4 that extend sampling box 2 bottom.
The ladle casting mechanism comprises a double-shaft motor 5, a sleeve 6, a rotating shaft 7 and a stainless steel ladle casting 8, the double-shaft motor 5 is arranged in the inner cavity of the sampling box 2 and close to the bottom, a motor shaft of the double-shaft motor 5 extends towards two sides and is connected with the sleeve 6 through a coupler 9, and the outer end of the sleeve 6 is fixedly connected with the stainless steel ladle casting 8 through the rotating shaft 7. One end of the rotation shaft 7 extends into the lumen of the cannula 6 and is connected to the inner wall of the cannula 6 by a compression spring 91. Limiting plates 10 for limiting the rotation angle of the rotating shaft 7 are fixed on the upper side and the lower side of the rotating shaft 7.
After the liquid taking and pouring mechanism is assembled with a seven-axis pouring arm of a pouring robot through an assembling head 1, the seven-axis pouring arm controls the liquid taking and pouring mechanism to extend into a crucible holding furnace filled with aluminum alloy liquid, a probe tube 4 extends out of the bottom of a sampling box 2 to detect the liquid level of the aluminum alloy liquid in advance, and when the liquid level meets the liquid taking requirement, the seven-axis pouring arm controls the sampling box 2 to move downwards so that a stainless steel pouring ladle 8 completely enters the aluminum alloy liquid to take liquid; the double-shaft motor 5 drives the sleeve 6 and the rotating shaft 7 to rotate through the coupler 9, so that the two stainless steel casting ladles 8 scoop aluminum alloy melt for casting simultaneously. When the height of the liquid level of the aluminum alloy melt is not enough, the piston rod of the telescopic cylinder 13 drives the transverse plate 12 to move upwards through the fixing block 14, the transverse plate 12 drives the detecting tube 4 to move upwards along the sliding chute 15, and meanwhile, the stainless steel casting ladle 8 can completely enter the aluminum alloy melt to scoop the aluminum alloy melt through the seven-axis casting arm inclined angle. This get liquid pouring mechanism controls two stainless steel through biax motor 5, revolving axle 7 and waters the synchronous liquid of 8, and the liquid level position that the position of cooperation detecting tube 4 removed with the adaptation aluminium alloy melt detects, is convenient for in time adjust get liquid angle or supply aluminium alloy melt. One end of the rotating shaft 7 is connected with the inner wall of the sleeve 6 through a compression spring 91, so that the vibration generated on the rotating shaft 7 when the stainless steel casting ladle 8 ladles the aluminum alloy melt is relieved.
Example 3
As shown in fig. 6 to 7, the present embodiment provides a sand blasting machine for separating a sand core from a surface of a brake caliper cooling semi-finished product by high-frequency hammering during doffing, cracking the sand core into a block, and removing the block and the break, and includes a frame 17, a hammering box 18, and a waste sand collecting chamber 19, wherein the hammering box 18 and the waste sand collecting chamber 19 are respectively disposed at the top and the bottom of the frame 17, a sound insulation chamber 20 is disposed inside the hammering box 18, and a sound insulation door 21 is mounted outside the sound insulation chamber 20. A high-frequency hammering mechanism and an oscillation positioning mechanism are arranged in the hammering box 18.
The sand beating machine is characterized in that the high-frequency hammering of the high-frequency hammering mechanism is matched with the positioning swing oscillation of the oscillation positioning mechanism, so that the sand core and the surface of a semi-finished product cooled by the brake caliper are quickly separated, cracked and scattered, the sand core falls into the waste sand collecting chamber 19 to be collected and is not easy to remain on the surface of the semi-finished product cooled by the brake caliper, the sand core clearing rate is enabled to reach more than 95% by combining the mode of the high-frequency hammering and the swing oscillation, and the sand core is not easy to remain in the sound insulation chamber 20.
As shown in fig. 7 to 9, the oscillation positioning mechanism includes a bevel gear reducer 22, a positioning frame 23 and a driving shaft 24, the bevel gear reducer 22 is fixed to the top of one side of the hammering box 18, the driving shaft 24 extending into the sound insulation chamber 20 is assembled to an output shaft of the bevel gear reducer 22, a driving gear 25 is fixed to an end of the driving shaft 24, a driven gear 26 is engaged below the driving gear 25, and a driven shaft 27 extending to the inner wall of the hammering box 18 is provided through the axis of the driven gear 26. The other side of hammering case 18 is equipped with first auxiliary shaft 28 that runs through to hammering case 18 inner wall, and first auxiliary gear 29 is fastened to first auxiliary shaft 28 and is located the end of sound proof housing 20. The first auxiliary gear 29 corresponds to the position of the driving gear 25. A second auxiliary gear 30 is meshed below the first auxiliary gear 29, a second auxiliary shaft 31 extending to the inner wall of the hammering box 18 penetrates through the axis of the second auxiliary gear 30, and a limit bearing 45 is arranged at the contact position of the peripheries of the driven shaft 27 and the second auxiliary shaft 31 and the inner wall of the hammering box 18. The end parts of the driven shaft 27 and the second auxiliary shaft 31 close to the soundproof room 20 are connected with V-shaped support frames 32, and a positioning frame 23 is connected between the bottoms of the two support frames 32.
When the oscillating positioning mechanism works, the positioning frame 23 is used for conducting adaptive clamping and fixing on a plurality of brake caliper cooling semi-finished products, the bevel gear reducer 22 drives the driving shaft 24 and the driving gear 25 to rotate, the driving gear 25 drives the driven gear 26 meshed with the driving gear to rotate, the driven gear 26 drives the driven shaft 27 to rotate, the support frame 32 and the positioning frame 23 are also driven to rotate by the rotation of the driven shaft 27, the support frame 32 drives the second auxiliary shaft 31 to synchronously rotate, the second auxiliary shaft 31 drives the second auxiliary gear 30 to rotate, and the second auxiliary gear 30 is meshed with the first auxiliary gear 29 to rotate due to the fixed position of the first auxiliary gear 29. By controlling the forward and reverse rotation of the bevel gear reducer 22, the support frame 32 and the positioning frame 23 form regular swinging oscillation, and the separation and removal of sand cores are promoted. The driven shaft 27, the first auxiliary shaft 28 and the second auxiliary shaft 31 respectively play a role in positioning and supporting the driven gear 26, the first auxiliary gear 29 and the second auxiliary gear 30, and the gear transmission keeps the stability and regularity of the swing oscillation of the positioning frame 23.
The driving gear 25 and the first auxiliary gear 29 have the same size, and the driven gear 26 and the second auxiliary gear 30 have the same size; a plurality of positioning grooves matched with the size of the semi-finished product cooled by the brake calipers are arranged in the positioning frame 23, and a plurality of through holes penetrate through the positioning frame 23. The top of the two sides of the frame 17 is provided with a high-speed blower 33, and the high-speed blower 33 is connected with an air supply pipe 34 extending to the upper part of the outer side of the positioning frame 23.
The periphery of the hammering box 18 adopts a steel structure frame, the periphery of the sound insulation chamber 20 is filled with sound absorption rock wool 35 with the thickness of more than or equal to 80mm, and the inner cavity of the frame 17 is positioned below the sound insulation chamber 20 and is provided with a plurality of layers of sand guide plates 36. High-speed wind generated by a high-speed blower 33 is blown into the positioning frame 23 and the brake calipers through a blast pipe 34 to cool the semi-finished product, so that separated sand cores enter the waste sand collecting chamber 19 through a sand guide plate 36, and the sand cores are prevented from remaining on the positioning frame 23.
As shown in fig. 7 and 10, the high-frequency hammering mechanism comprises a high-frequency air hammer 37, a mounting cavity 38 and a hammer head 39, an air inlet head 40 is arranged at the top of the high-frequency air hammer 37, an air inlet pipe 41 is connected to the top of the air inlet head 40, the hammer head 39 is arranged at the bottom of the high-frequency air hammer 37, damping rubber 42 is assembled at the bottom of the hammer head 39, the hammering direction of the hammer head 39 faces the positioning frame 23, the air inlet head 40 extends into the mounting cavity 38 at the top of the soundproof chamber 20, mounting plates 43 are fixed on two sides of the high-frequency air hammer 37, and a hydraulic oil cylinder 44 connected with the air inlet head 40 is arranged at the top of the mounting cavity 38.
When the high-frequency hammering mechanism works, compressed air enters the air inlet head 40 from the air inlet pipe 41, and the high-frequency air hammer 37 drives the hammer head 39 to perform high-frequency hammering on the surface of the brake caliper cooling semi-finished product, so that the sand core and the brake caliper cooling semi-finished product are separated and cracked. The hydraulic oil cylinder 44 drives the air inlet head 40 to move along the mounting cavity 38, and the high-frequency air hammer 37 moves along the inner cavity of the mounting plate 43, so that the hammering position of the hammer head 39 can be conveniently adjusted; the damper rubber 42 relieves the instantaneous hammering pressure of the hammer head 39.
The foregoing is merely illustrative and explanatory of the present invention, and various modifications, additions or substitutions as would be apparent to one skilled in the art to the specific embodiments described are possible without departing from the invention as claimed herein or beyond the scope thereof.
In the description herein, references to the description of "one embodiment," "an example," "a specific example," etc., mean that a particular feature, structure, material, or characteristic described in connection with the embodiment or example is included in at least one embodiment or example of the invention. In this specification, the schematic representations of the terms used above do not necessarily refer to the same embodiment or example. Furthermore, the particular features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples.
The preferred embodiments of the invention disclosed above are intended to be illustrative only. The preferred embodiments are not intended to be exhaustive or to limit the invention to the precise form disclosed. Obviously, many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to best explain the principles of the invention and the practical application, to thereby enable others skilled in the art to best utilize the invention. The invention is limited only by the claims and their full scope and equivalents.
Claims (10)
1. Automatic processing technology of new energy automobile brake caliper, its characterized in that includes the following steps:
s1, automatic core setting: taking off the sand core of the brake caliper of the new energy automobile from the double-layer sand core table through a sand core placing robot and placing the sand core on a sand core mould of the gravity casting machine;
s2, pouring: scooping the aluminum alloy melt from the crucible holding furnace by adopting a pouring robot provided with a seven-axis pouring arm and a liquid taking and pouring mechanism, and pouring the aluminum alloy melt into a sand core mold of a gravity casting machine to obtain a poured semi-finished product;
s3, taking a workpiece: taking down the casting semi-finished product by the taking-out clamp and hanging the casting semi-finished product on an air cooling frame;
s4, cooling: an air cooling frame provided with an axial flow fan is used for cooling the poured semi-finished product to room temperature to obtain a cooled semi-finished product; a sand core collecting box is arranged below the air cooling frame;
s5, defect detection: the post-processing robot takes the cooled semi-finished product down from the air cooling frame, places the cooled semi-finished product on a sampling inspection table, adopts CCD visual inspection to detect whether the cooled semi-finished product has defects, and screens out qualified cooled semi-finished products;
s6, doffing: the post-processing robot places the qualified cooled semi-finished product on a sand blasting machine, separates the cooled semi-finished product from the sand core on the surface in a high-frequency hammering and swinging oscillation mode, cracks the cooled semi-finished product into blocks, breaks away and clears away the blocks to obtain a doffed semi-finished product;
s7, cutting: cutting and removing a pouring gate of the doffing semi-finished product by adopting a double-station automatic cutting machine to obtain a cut semi-finished product;
s8, deburring: deburring the parting line of the cut semi-finished product by adopting a deburring robot with a deburring tool to obtain a finished product of the brake caliper of the new energy automobile;
s9, outputting the next piece: and the post-processing robot places the finished new energy automobile brake caliper on a plate chain conveying line to finish unloading.
2. The automatic processing technology of the new energy automobile brake caliper is characterized in that the specification and model of the sand core placing robot is R-2000 IC/165; the double-layer sand core platform comprises a double-layer shuttle platform, eight-mold sand cores are placed on each layer of shuttle platform, and the new energy automobile brake calipers are double-cylinder calipers.
3. The automatic processing technology of the new energy automobile brake caliper is characterized in that the specification and model number of the pouring robot is R-2000 IC/165; two sand core molds are arranged in the gravity casting machine, the force of a mold opening oil cylinder is 44kN, the force of a mold closing oil cylinder is 47kN, and the cycle beat of each gravity casting machine is less than or equal to 256 s/mold.
4. The automatic processing technology of the new energy automobile brake caliper is characterized in that the compressed air pressure is 0.6MPa and the consumption is 18000L/h when the high-frequency hammering is performed.
5. The automatic processing technology of the new energy automobile brake caliper is characterized in that compressed air is introduced into the double-station automatic cutting machine, the pressure of the compressed air is 0.6MPa, the consumption is 100L/h, and the cutting precision is +/-0.5 mm.
6. The automatic processing technology of the new energy automobile brake caliper is characterized in that the deburring residual quantity of the parting line is 0-0.4 mm, and the deburring beat is less than or equal to 43s per piece.
7. The automatic processing technology of the new energy automobile brake caliper is characterized in that the liquid taking and pouring mechanism comprises an assembling head (1), a sampling box (2) and a sampling cover (3), the assembling head (1) is fixedly arranged at the top of the sampling box (2), the sampling cover (3) is arranged outside the sampling box (2) in a covering mode and is fastened through bolts (16), the position, close to the bottom, of the sampling box (2) is rotatably connected with a ladle mechanism, and two detecting tubes (4) extending out of the bottom of the sampling box (2) are arranged in an inner cavity of the sampling box (2);
the ladle casting mechanism comprises a double-shaft motor (5), a sleeve (6), a rotating shaft (7) and a stainless steel ladle casting (8), the double-shaft motor (5) is arranged at the position, close to the bottom, of the inner cavity of the sampling box (2), a motor shaft of the double-shaft motor (5) extends towards two sides and is connected with the sleeve (6) through a coupler (9), and the outer end of the sleeve (6) is fixedly connected with the stainless steel ladle casting (8) through the rotating shaft (7); one end of the rotating shaft (7) extends into the inner cavity of the sleeve (6) and is connected with the inner wall of the sleeve (6) through a compression spring (91); limiting plates (10) for limiting the rotation angle of the rotating shaft (7) are fixed on the upper side and the lower side of the rotating shaft (7);
position detection sensor (11) are installed to the inner chamber of detecting tube (4), and the top of two detecting tube (4) is connected with diaphragm (12), and the top of sampling box (2) is fixed with telescopic cylinder (13), and telescopic cylinder's (13) piston rod passes through fixed block (14) and diaphragm (12) fixed connection, is equipped with in sampling box (2) and supplies gliding spout (15) of detecting tube (4).
8. The automatic processing technology of the new energy automobile brake caliper is characterized in that the sand blasting machine comprises a rack (17), a hammering box (18) and a waste sand collecting chamber (19), the hammering box (18) and the waste sand collecting chamber (19) are respectively arranged at the top and the bottom of the rack (17), a sound insulation chamber (20) is arranged inside the hammering box (18), and a sound insulation door (21) is arranged outside the sound insulation chamber (20); a high-frequency hammering mechanism and an oscillation positioning mechanism are arranged in the hammering box (18).
9. The automatic processing technology of the new energy automobile brake caliper is characterized in that the oscillation positioning mechanism comprises a bevel gear speed reducer (22), a positioning frame (23) and a driving shaft (24), the bevel gear speed reducer (22) is fixed to the top of one side of the hammering box (18), the driving shaft (24) extending into the sound insulation chamber (20) is assembled on an output shaft of the bevel gear speed reducer (22), a driving gear (25) is fixed to the end of the driving shaft (24), a driven gear (26) is meshed below the driving gear (25), and a driven shaft (27) extending to the inner wall of the hammering box (18) penetrates through the axis of the driven gear (26); a first auxiliary shaft (28) penetrating to the inner wall of the hammering box (18) is arranged on the other side of the hammering box (18), and a first auxiliary gear (29) is fastened on the end, located on the soundproof room (20), of the first auxiliary shaft (28); a second auxiliary gear (30) is meshed below the first auxiliary gear (29), a second auxiliary shaft (31) extending to the inner wall of the hammering box (18) penetrates through the axis of the second auxiliary gear (30), and a limiting bearing (45) is arranged at the contact position of the peripheries of the driven shaft (27) and the second auxiliary shaft (31) and the inner wall of the hammering box (18); the end parts of the driven shaft (27) and the second auxiliary shaft (31) close to the soundproof room (20) are connected with V-shaped support frames (32), and a positioning frame (23) is connected between the bottoms of the two support frames (32).
10. The automatic processing technology of the new energy automobile brake caliper is characterized in that high-speed blowers (33) are arranged at the tops of two sides of the frame (17), and the high-speed blowers (33) are connected with air supply pipes (34) extending to the upper part of the outer side of the positioning frame (23); the periphery of the hammering box (18) adopts a steel structure frame, the periphery of the sound insulation chamber (20) is filled with sound absorption rock wool (35) with the thickness of more than or equal to 80mm, and a plurality of layers of sand guide plates (36) are arranged below the inner cavity of the frame (17) and positioned in the sound insulation chamber (20).
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| JPS6397357A (en) * | 1986-10-15 | 1988-04-28 | Aisin Seiki Co Ltd | Alternate metallic mold exchange type vertical casting device |
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