Digital production apparatus for engineered composite material precision forming
Technical field
The present invention relates to a kind of digital production apparatus for engineered composite material precision forming.
Background technology
In recent years, substitute traditional metal materials as the key components and parts in the machine driven system with novel engineered composite material, with natural water or solid lubricant substitute mineral oil as the lubricant medium in the machine driven system, based on the bearing in resources conservation and the eco-friendly high efficient driving system, seal, shaft coupling, important foundation parts such as damper, because of having damping, noise reduction, wear-resisting, reliably, efficiently, energy-conservation, remarkable advantage such as material-saving and environmental protection is extensively applied to machinery, boats and ships, vehicle, aviation, space flight, oil, chemical industry, engineering such as water conservancy and agricultural field.
The typical traditional processing technology of engineered composite material goods is to adopt the hot pressing of steam heat pressure type resistance conducts, promptly carry out the mold pressing heating by heated plate up and down, the hand-guided control hydraulic system carries out processes such as lifting and pressurization to workpiece, its shortcoming is: 1. each the position hot pressing of vulcanization forming engineered composite material goods is inhomogeneous, the hot-press vulcanization time is long, and the efficient heat utilization is few; 2. can not carry out stable holding pressure control to the workpiece in the sulfuration; 3. can not monitor and measure for parameters such as the temperature of vulcanizing system, pressure, times, technological parameter can not onlinely be stored, can not realize servo observing and controlling to production process, the molded vulcanization process of workpiece is uncontrollable carries out in optimizing the efficient vulcanization process parameters range of setting, thereby make workpiece after through the molded vulcanization forming technology, can not disposablely meet the requirements of the dimensional tolerance precision, product surface is rough, out-of-flatness, have layering to have problems such as burr and crackle, also will be through subsequent treatment such as fine finishining repeatedly; And key technology performance indications such as bearing capacity of product, operating rate, friction factor, dimensional stability, surface roughness be difficult to reach requirement; 5. vulcanizer is installed inconvenience, and production efficiency is low, and manipulation strength is big, and reliability is relatively poor, can not ensure safety in production.
Summary of the invention
Purpose of the present invention designs a kind of eddy-current heating that fast, evenly vulcanizes exactly, die pressure is controlled, the efficient vulcanization process system is carried out computer servo control, the digital production apparatus for engineered composite material precision forming that product only needs disposable molded vulcanization to be shaped and just can to reach the dimensional tolerance precision and its key technology performance indications are significantly increased.
A kind of digital production apparatus for engineered composite material precision forming involved in the present invention comprises vulcanizer stand, thrust hydraulic cylinder, hydraulic loading system, inductive heating moulding, the integrated TT﹠C system of PLC numeral.The vulcanizer stand is made of base 1, hoistable platform 25, top cover 20, four cylinders 15, the lower end step of cylinder 15 is pressed in and forms matched in clearance in base 1 groove, the upper end step that the groove of top cover 20 is pressed in cylinder 15 forms matched in clearance, nut 19 and nut 13 are locked at cylinder 15 on top cover 20 and the base 1, two of cylinder 15 has spline, position sensor 16 and position sensor 18 on cylinder 15.The thrust hydraulic cylinder is made up of hydraulic cylinder 5, end cap 8, end cap 12, plunger 7, have screwed hole 6 and screw thread oilhole 4 on the hydraulic cylinder 5, screw thread oil pipe 2 connects hydraulic cylinder 5 and base 1, pressure sensor 29 is housed in the screwed hole 6, sealing ring 3 is equipped with in plunger 7 outer faces, end cap 12 inner faces are equipped with sealing ring 26 and sealing ring 10, plunger 7 can vertically move up and down, end cap 8 bottom faces are equipped with sealing ring 11 and have offered screwed hole 27, screw thread oil pipe 28 is installed in the screwed hole 27, and end cap 8 circumferentially evenly divides other screw 9 to be connected with end cap 12 by 6.Hydraulic loading system comprises high-pressure pump 30, high-pressure pump 31, overflow valve 32, electromagnetic proportional valve 33, electric-controlled switch valve 34, check valve 35, check valve 36, electric-controlled switch valve 37, electromagnetic proportional valve 38, overflow valve 39.Inductive heating moulding comprises induction heating power 14, temperature sensor 23, induction coil 24, and temperature sensor 23 inserts in the workpiece 22, and induction coil 24 is coiled in the outer surface of workpiece 22.The data wire of temperature sensor 23, pressure sensor 29, position sensor 16 and position sensor 18 directly links to each other with PLC industrial computer I/O port in the integrated TT﹠C system of PLC numeral, induction heating power 14, high-pressure pump 30, high-pressure pump 31, electromagnetic proportional valve 33, electric-controlled switch valve 34, electric-controlled switch valve 37, electromagnetic proportional valve 38, button relay-set 17 link to each other with PLC industrial computer I/O port with the D/A modular converter by the A/D modular converter, and the PLC industrial computer is by adapter conversion and computer communication.
Digital production apparatus for engineered composite material precision forming involved in the present invention, the vulcanizer stand is easy installation and reliable, the workbench lifting quick and stable.The sulfuration process of workpiece adopts eddy-current heating and hydraulic pressure dynamically to pressurize, and each the position hot pressing of the formed rubber products of sulfuration is even, and the hot-press vulcanization time is short, and heat can be utilized effectively.Simultaneously, the integrated TT﹠C system of sulfuration process employing PLC numeral of workpiece can be respectively to inductive heating moulding, the efficient vulcanization process system, hydraulic loading systems etc. carry out SERVO CONTROL, the actual process data of online record storage and immediate feedback processing site are given computer control system, the forming process of workpiece is controlled in the efficient vulcanization process system of institute's optimal design after disposable the finishing all the time, just can reach the dimensional tolerance precision of product fully, the engineered composite material smooth surface, smooth, no layering, there is not crackle, impurity, burr, bubble, problems such as glue knurl and shelling improve product quality and production efficiency greatly.The present invention has workpiece quality and controls easily, and handling safety is reliable, efficient, energy-conservation, material-saving, advantages of environment protection.
Description of drawings
Fig. 1 is the front view of digital production apparatus for engineered composite material precision forming, and it also is the A-A sectional view of Fig. 3.
Fig. 2 is the right view of digital production apparatus for engineered composite material precision forming.
Fig. 3 is the structural representation of digital production apparatus for engineered composite material precision forming.It also is the B-B sectional view of Fig. 1
Fig. 4 is a thrust hydraulic cylinder structure schematic diagram, also is the E-E sectional view of Fig. 5.
Fig. 5 is a thrust hydraulic cylinder structure schematic diagram, also is the C-C sectional view of Fig. 4.
Fig. 6 is a thrust hydraulic cylinder structure schematic diagram.It also is the D-D sectional view of Fig. 4.
Fig. 7 is the hydraulic schematic diagram of hydraulic loading system.
Fig. 8 is the integrated TT﹠C system control principle figure of PLC numeral.
Fig. 9 is a workpiece water lubricating composite rubber bearing end view drawing
Figure 10 is a workpiece water lubricating composite rubber bearing structural representation, also is the F-F sectional view of Fig. 9
1. bases among the figure, 2. screw thread oil pipe, 3. sealing ring, 4. screw thread oilhole, 5. hydraulic cylinder, 6. screwed hole, 7. plunger, 8. end cap, 9. screw, 10. sealing ring, 11. sealing rings, 12. end caps, 13. nut, 14. induction heating powers, 15. cylinders, 16. position sensor, 17. button relay-sets, 18. position sensors, 19. nut, 20. top covers, 21. clamping moulds, 22. workpiece, 23. temperature sensors, 24. induction coils, 25. hoistable platform, 26. sealing rings, 27. screwed holes, 28. the screw thread oil pipe, 29. pressure sensors, 30. high-pressure pumps, 31. high-pressure pump, 32. overflow valves, 33. electromagnetic proportional valves, 34. the electric-controlled switch valve, 35. check valves, 36. check valves, 37. the electric-controlled switch valve, 38. electromagnetic proportional valves, 39. overflow valves.
The specific embodiment
The present invention will be further described below in conjunction with drawings and Examples:
A kind of digital production apparatus for engineered composite material precision forming involved in the present invention comprises vulcanizer stand, thrust hydraulic cylinder, hydraulic loading system, inductive heating moulding, the integrated TT﹠C system of PLC numeral.As shown in Figure 1, the vulcanizer stand is made of base 1, hoistable platform 25, top cover 20, four cylinders 15.The lower end step of cylinder 15 is pressed in and forms matched in clearance in base 1 groove.The upper end step that the groove of top cover 20 is pressed in cylinder 15 forms matched in clearance.Cylinder 15 is locked on top cover 20 and the base 1 by nut 19 and nut 13, and top cover 20 adjustment level and centerings.Two of cylinder 15 has spline, the convenient stand of installing.Position sensor 16 and position sensor 18 detect the hoistable platform 25 motion lower limit and the upper limits on cylinder 15.
As shown in Figure 1 and Figure 4, the thrust hydraulic cylinder is made up of hydraulic cylinder 5, end cap 8, end cap 12, plunger 7.Have screwed hole 6 and screw thread oilhole 4 on the hydraulic cylinder 5.As Fig. 2 and shown in Figure 6, pressure sensor 29 is housed in the screwed hole 6 detects oil pressure in the thrust hydraulic cylinder.As shown in Figure 1, sealing ring 3 is equipped with in plunger 7 outer faces, prevents that the hydraulic oil of plunger 7 upper and lower cavities from leaking mutually.End cap 12 inner faces are equipped with sealing ring 26 and sealing ring 10 and end cap 8 bottom faces sealing ring 11 are housed, and all are to prevent that hydraulic fluid leak from going out.Plunger 7 can vertically move up and down.End cap 8 has been offered screwed hole 27.Hydraulic oil is by being installed in the screw thread oil pipe 28 and the screw thread oil pipe 2 turnover thrust hydraulic cylinders that are connected hydraulic cylinder 5 and base 1 in the screwed hole 27.6 are circumferentially evenly divided other screw 9 that end cap 8 and end cap 12 are pressed together.
As shown in Figure 7, hydraulic loading system comprises high-pressure pump 30, high-pressure pump 31, overflow valve 32, electromagnetic proportional valve 33, electric-controlled switch valve 34, check valve 35, check valve 36, electric-controlled switch valve 37, electromagnetic proportional valve 38, overflow valve 39.Store hydraulic oil in the thrust hydraulic cylinder, the lower surface by plunger 7 is divided into epicoele and cavity of resorption to thrust hydraulic cylinder inner chamber.When wanting hoistable platform 25 to rise, hydraulic loading system is implemented plunger 7 ascending schemes, promptly is that electric-controlled switch valve 34 cuts out, and electric-controlled switch valve 37 is opened, and high-pressure pump 31 is pumped into cavity of resorption to the hydraulic oil of epicoele by electromagnetic proportional valve 33, thereby plunger 7 is moved up; Otherwise when wanting hoistable platform to rise for 25 times, hydraulic loading system is implemented plunger and is risen scheme 7 times, promptly be that electric-controlled switch valve 34 is opened, electric-controlled switch valve 37 cuts out, and high-pressure pump 30 is pumped into epicoele to the hydraulic oil of cavity of resorption by electromagnetic proportional valve 38, thereby plunger 7 is moved down.Workpiece is in sulfidation, sulfide stress will be stabilized in the operation pressure value scope of setting, raise as pressure in the sulfuration, hydraulic loading system is just implemented plunger and is risen scheme 7 times, changes the sulfide stress that the hydraulic fluid flow rate size comes stable reduction workpiece to be subjected to by regulating electromagnetic proportional valve 38 simultaneously; Otherwise the pressure that is subjected to as workpiece in vulcanizing reduces, and hydraulic loading system is just implemented plunger 7 ascending schemes, changes the sulfide stress that the big or small next stable reduction workpiece of hydraulic fluid flow rates is subjected to by regulating electromagnetic proportional valve 33 simultaneously.
As shown in Figure 1, inductive heating moulding comprises induction heating power 14, temperature sensor 23, induction coil 24.Temperature sensor 23 inserts in the workpiece 22, induction coil 24 is coiled in the outer surface of workpiece, the electric current of the different frequency by computer control induction heating power 14 output is to induction coil 24, thus can produce as required different heats to workpiece 22 carry out fast, uniform heating.
As shown in Figure 8, the data wire of temperature sensor 23, pressure sensor 29, position sensor 16 and position sensor 18 directly links to each other with PLC industrial computer I/O port in the integrated TT﹠C system of PLC numeral.Induction heating power 14, high-pressure pump 30, high-pressure pump 31, electromagnetic proportional valve 33, electric-controlled switch valve 34, electric-controlled switch valve 37, electromagnetic proportional valve 38, button relay-set 17 link to each other with PLC industrial computer I/O port with the D/A modular converter by the A/D modular converter, and the PLC industrial computer is by adapter conversion and computer communication.The integrated TT﹠C system of PLC numeral can be realized sulfuration process parameter control such as curing temperature, sulfide stress and cure times.Be sent in the PLC industrial computer by position sensor 18 and position sensor 16 data, can control the upper limit of movement and the lower limit of hoistable platform.Be sent in the PLC industrial computer by temperature sensor 23 and pressure sensor 29 data, realize monitoring respectively to the temperature and pressure of inductive heating moulding and hydraulic loading system, compare with the technological parameter of setting, the variation difference that produces is handled in the system that compensates to separately by the program of PLC industrial computer software programming and is gone, thereby realized the SERVO CONTROL of production process, the sulfidation of workpiece is controlled in the process parameters range of setting all the time carries out, guaranteed the quality of product.Important technical parameter in process of production can be saved in the database timely simultaneously.
Embodiment:
Shown in Fig. 9~10, the engineered composite material workpiece goods that vulcanized are that internal diameter 20~160mm, external diameter 35~205mm, length are the water lubricating composite rubber bearing of 40~320mm scope, and its liner is that compounded rubber, shell are admirality brass.As shown in figures 1 and 3, compounded rubber is expressed in the workpiece mould, its workpiece mold cramping location and installation is placed on the hoistable platform 25 with anchor clamps.Temperature sensor 23 is installed in the workpiece 22, and induction coil 24 is coiled on the workpiece outer surface.PLC industrial computer hardware group adopts Siemens S7-300PLC, CPU314,16 T/O port, assemblies such as PS307.The temperature sensor 23 of digital quantity output, pressure sensor 29, position sensor 16 and position sensor 18 DI ports direct and the PLC industrial computer join.Induction heating power 14, high-pressure pump 30, high-pressure pump 31, electromagnetic proportional valve 33, electric-controlled switch valve 34, electric-controlled switch valve 37, electromagnetic proportional valve 38, button relay-set 17 link to each other with PLC industrial computer I/O port with the D/A modular converter by the A/D modular converter, the PLC industrial computer links to each other with computer by adapter, adopts STEP7 software to carry out program composition.
Configuring the technological parameter curing temperature, sulfide stress, behind the cure time, the integrated TT﹠C system of PLC numeral control hydraulic loading system electric-controlled switch valve 34 is earlier closed, electric-controlled switch valve 37 is opened, start high-pressure pump 31 hydraulic oil of epicoele in the thrust hydraulic cylinder is passed through screw thread oil pipe 28 successively, proportion magnetic valve 33 and screw thread oil pipe 2 are pumped into cavity of resorption, make plunger 7 upwards promote hoistable platform 25 workpiece mould 21 roof pressures on top cover 20, guarantee the rising of crossing of hoistable platform 25 by position sensor 18, the output pressure of hydraulic oil is till the sulfide stress value of setting, and proportion magnetic valve 33 is closed.Then, 24 energisings of 14 pairs of induction coils of the integrated TT﹠C system control induction heating power of PLC numeral make workpiece reach the curing temperature of setting.Workpiece is in sulfuration work, the temperature and pressure transfer of data that produces when temperature sensor and the sulfuration of pressure sensor handle is in the PLC industrial computer, compare with the sulfuration process parameter of setting, the variation difference that produces is handled by the program of PLC industrial computer software STEP7 establishment, difference is compensated to induction heating power 14 respectively, change the frequency of output current, make 24 pairs of workpiece of induction coil produce heating-up temperature and the hydraulic loading system of setting, the opening amount that changes proportion magnetic valve is adjusted the pressure of thrust hydraulic cylinder to the sulfide stress of setting.Simultaneously, the technological parameter in the sulfidation is saved in the database.After the cure time of setting finished, the integrated TT﹠C system control of PLC numeral induction heating power 14 was closed, and stops the heating to workpiece.Then, control hydraulic loading system electric-controlled switch valve 34 is opened, electric-controlled switch valve 37 cuts out, high-pressure pump 30 is delivered to the hydraulic oil pump of cavity of resorption and is promoted plunger 7 in the epicoele, thereby make hoistable platform 25 steadily drop to starting point reliably by position sensor 16 detections, thereby finished the workpiece sulfidation.
After workpiece was shaped through sulfuration process, the dimensional tolerance of workpiece is the disposable precision prescribed that reaches regulation of energy just, does not need to carry out grinding (as shown in table 1) again.The rubber surface roughness of bearing is Ra0.025 μ m, smooth surface, smooth, no layering, there are not problems such as crackle, impurity, burr, bubble, glue knurl and shelling, cure time shortened to 10~80 minutes in 40~150 minutes from traditional cure time, each position hot pressing of workpiece is even, and curing temperature and pressure are controlled easily in the sulfidation.
Table 1 engineered composite material precision form workpiece liner radial thickness dimensional tolerance precision
The workpiece of different inner diameters dimensions | Workpiece liner radial thickness dimensional tolerance precision (mm) |
20~35mm 3/4″~1-3/8″in | ±0.025~±0.05 |
35~45mm 1-7/16″~1-7/8″in | ±0.03~±0.06 |
50~120mm 2″~2-3/8″in | ±0.04~±0.08 |
60~75mm 2-1/2″~3″in | ±0.05~±0.10 |
80~95mm 3-1/8″~3-3/4″in | ±0.06~±0.12 |
100~105mm 3-7/8″~4-1/4″in | ±0.07~±0.14 |
110~125mm 4-3/8″~4-7/8″in | ±0.09~±0.16 |
125~135mm 5″~5-3/8″in | ±0.11~±0.18 |
150~160mm 6″~6-3/8″in | ±0.15±0.22 |
Table 2,3,4 has carried out experiment to key technology performance indications such as the bearing capacity of vulcanize physical and chemical performance, absorbability and the workpiece thereof of the workpiece inner lining material that, operating rate, friction factors respectively and has detected, and the every performance indications of this workpiece all reach and part has surpassed the MIL-B-17901B of U.S. Department of Defense (boats and ships) military standard.Improved more than ten times than metal bearing service life and made to have improved service life and be about three times, had significant combination property advantage than external similar bearing.
Table 2 vulcanizes the physical and chemical performance of the workpiece inner lining material that
Project | This workpiece | MILSTD |
Deformation load | 1.6N/mm
2 | 2.1N/mm
2 | 1.6N/mm
2 | 2.1N/mm
2 |
Amount of deflection | 0.0925mm | 0.1023mm | 0.1016mm | 0.1142mm |
Compression strength | 238N/mm
2 | 105N/mm
2 |
Tensile strength | 54N/mm
2 | 21N/mm
2 |
External diameter shrinks | 0.0482-0.0603mm | 0.0508-0.0635mm |
Table 3 vulcanizes the absorbability (shrinkage factor) of the workpiece inner lining material that
Time | Liquid | Temperature | This workpiece | U.S. army mark |
70hrs | ASTM#30il | 100℃ | +2.9% | +4.0% |
70hrs | ASTM#30il | 38℃ | <+1% | <+1% |
70hrs | ASTM#30il | 22℃ | Ignore | Ignore |
70hrs | H0 | 100℃ | +1.8% | +2.6% |
70hrs | H0 | 38℃ | Ignore | Ignore |
Table 4 vulcanizes the workpiece key technology performance indications that
Experimental project | This workpiece | U.S. BFGoodrich | Britain BTR |
Bearing capacity | 0.382N/mm
2 | 0.246N/mm
2 | 0.25N/mm
2 |
Operating rate | 0.025-40m/s | 0.04-40m/s | 0.05-35m/s |
Friction factor | 0.008-0.015 | 0.0015-0.025 | 0.01-0.02 |
Amount of deflection | 0.1016-0.1143mm | 0.1139-0.1248mm | 0.1040-0.1235mm |
Compression strength | 238N/mm
2 | 208N/mm
2 | 225N/mm
2 |
Tensile strength | 54N/mm
2 | 49N/mm
2 | 51N/mm
2 |
External diameter shrinks | 0.0508-0.0635mm | 0.0569-0.0645mm | 0.0507-0.0673mm |
Volume Changes | Less than 1% | Less than 2.3% | 1.5% |
Operating temperature | -20-86℃ | -20-80℃ | -20-86℃ |
Service life | 4500.00 | 12500h | 1500h |
Combination property | First | Second | The 3rd |