The specific embodiment
The utility model is described in further detail below in conjunction with accompanying drawing and by embodiment.
Embodiment: referring to Fig. 1, the utility model embodiment comprise cylinder body lot number mark machine 1, oil outlet steel ball pressing machine 2, dress centre valve machine 3, second piston assembly assembling detection machine 4, first piston assembly assembling detection machine 5, second piston pack into cylinder body machine 6, first piston pack into cylinder body machine 7, exercise test machine 8, two air tightness test machine 9, fuel inlet fitting and lubricating cup assembly machine 10, sealing and return time test machine 11, dress dust cap workbench 12, check packing workbench 13.
Cylinder body lot number mark machine 1 and oil outlet steel ball pressing machine 2 cooperate, oil outlet steel ball pressing machine 2 also cooperates with second piston cylinder body machine 6 and the first piston cylinder body machine 7 of packing into of packing into respectively, dress centre valve machine 3 cooperates with second piston assembly assembling detection machine 4 and first piston assembly assembling detection machine 5 respectively, second piston assembly assembling detection machine 4 also cooperates with second piston cylinder body machine 6 of packing into, first piston assembly assembling detection machine 5 also cooperates with the first piston cylinder body machine 7 of packing into, exercise test machine 8, two air tightness test machines 9, fuel inlet fitting and lubricating cup assembly machine 10, sealing and return time test machine 11, dress dust cap workbench 12, check that packing workbench 13 cooperates successively, exercise test machine 8 also cooperates with second piston cylinder body machine 6 and the first piston cylinder body machine 7 of packing into of packing into respectively, and second piston cylinder body machine 6 and the first piston cylinder body machine 7 of packing into of packing into cooperates.Specifically:
Cylinder body lot number mark machine 1 is first station.This machine is power with compressed air, adopts pneumatic marking machine printed product sign on request on cylinder body end face or arc surface.
Oil outlet steel ball pressing machine 2 is second station.This machine is used to compensate cellular type master cylinder body pressing steel balls and oil outlet, with the steel ball pressing machine steel ball is pressed into cylinder body, with air press oil outlet correctly is pressed into.PLC+touch-screen control can select manual automatic mode operation.
Dress centre valve machine 3 is the 3rd station.This machine dress centre valve leather cup, in the time of leather cup feed bin sky, feed bin is opened automatically, prevents that the leather cup dress is wrong.
Second piston assembly assembling detection machine 4 is the 4th station.
First piston assembly assembling detection machine 5 is the 5th station.This machine is the 4th station together, integrates automatic assembling, vision-based detection, air-tightness detection, fog lubrication, and PLC+touch-screen control with upper machine communication, shows testing result and file in real time.Have loading error, neglected loading warning, the defective warning of vision, air-tightness detects functions such as defective warning, can select manual automatic mode operation.A tractor serves several purposes, replaceable frock detects with the assembling of adaptive compensation formula master cylinder.
Second piston cylinder body machine 6 of packing into is the 6th station.This machine function is cylinder body fog lubrication, second piston element cylinder body of packing into.The control of PLC+ touch-screen can be selected manual automatic mode operation.
The first piston cylinder body machine 7 of packing into is the 7th station.This machine function is that first piston is pressed into cylinder body and is installed the spring back-up ring.The control system that this device is made up of PLC Programmable Logic Controller and color touch screen is controlled, and measurement, demonstration, the whole process of acceptance or rejection (reporting to the police with indicator lamp) are Automatic Control; This special plane divides manual, automatic two kinds of patterns, and various parameters, manual switching can be by the touch-screen setting.
Exercise test machine 8 is the 8th station, is smoothness, idle stroke, total travel, ride comfort test special plane.This machine promotes smoothness, idle stroke, total travel, initiating power, total travel power and the release force that piston is tested master cylinder by equipment, detects piston by sensor and whether have catching phenomenon in motion process.
This machine is by the control of upper and lower machine, and host computer adopts industrial computer, and slave computer adopts the controlled programmable device of band analog quantity, comprises two-way vacuum test system and two cover air pressure test macros.
Measure air pressure with the control of secondary accurate voltage regulating valve, measure its displacement with rotary encoder, barometric surveying adopts high-precision vertical compression sensor measurement.Measuring process is manually and automatically to control.Pressure is presented on the display.Linear drives adopts the electronic cylinder of stepping.Power is measured employing power sensor.
Two air tightness test machines 9 are the 9th station and the tenth worker, are the double special plane, are used for high pressure air tightness test and high vacuum air tightness test.
This machine is controlled by the upper and lower machine, and host computer adopts industrial computer, and slave computer adopts the controlled programmable device of band analog quantity, measures air pressure secondary accurate voltage regulating valve control, and barometric surveying adopts high-precision vertical compression sensor measurement.Measuring process is manually and automatically to control.Pressure is presented on the display, the acceptance or rejection sound and light alarm.
Fuel inlet fitting and lubricating cup assembly machine 10 are the 11 station, and function is that lubricating cup or fuel inlet fitting are pressed on the master cylinder, and pivot pin or elastic cylindrical pin are pressed onto on the master cylinder.
This machine is compressed into oily joint and lubricating cup and is adopted pneumohydraulic pressure-cylinder to press-fit by electric and pneumatic control, and pad adopts cylinder to press-fit.Change frock, a tractor serves several purposes according to different product.
Sealing and return time test machine 11 are twelve-station.This machine is mainly tested the sealing of cylinder piston and leather cup, the air-tightness of fluid reservoir, the return time of piston.
This machine is by the control of upper and lower machine, and host computer adopts industrial computer, and slave computer adopts the controlled programmable device of band analog quantity, comprises two-way vacuum test system and 2 cover air pressure test macros.
Measure air pressure with the control of secondary accurate voltage regulating valve, measure its displacement with shifter, barometric surveying adopts leakage instrument to detect.Measuring process is manually and automatically to control.Pressure is presented on the display.Air cylinder driven, pneumatic shutoff.The acceptance or rejection sound and light alarm.
Dress dust cap workbench 12 is the 13 station.
Check that packing workbench 13 is the 14 station.
Above-mentioned each machine all disposes waste product runner and collecting receptacle.Press-fit the back defective work and flow out, and take out by the professional by this runner.And defective work has only after this runner outflow, and this station can continue operation.
Present embodiment is according to technological process, presses the T font and arranges, and wherein the assembling of the first piston assembly and second piston assembly detects and carries out simultaneously, by deposit platform temporarily, enters cylinder body machine 6 and first piston cylinder body machine 7 assemblings of packing into of packing into of second piston respectively and detects.According to each station beat, all there is one to deposit platform between per two machines, convenient turnover temporarily.
The technological process of production is as follows:
At first, the workman enters first station with cylinder body by stock shelf.By industrial control computer control cylinder body lot number mark machine 1, industrial control computer generates label automatically, carries out the mark of cylinder body lot number by cylinder body lot number mark machine 1.
Enter second station behind first station.Oil outlet steel ball pressing machine 2 starts the both hands starting switch, and the air cylinder driven anchor clamps clamp cylinder body, and by vibrating disk reason material, material loading enters pressing machine, and press starts.Pressing down puts in place resets after qualified and finishes to press-fit, and cylinder body enters second piston cylinder body machine 6 of packing into; Defective, report to the police, put into collecting receptacle.
Dress centre valve machine 3 begins to adorn centre valve, two leather cups of assembly center valve, assembling is finished and is put into the detection frock, carries out vision-based detection, whether the leather cup direction is correct, the qualified next process that then flows into: adorn second piston assembly assembling detection machine 4 and first piston assembly assembling detection machine 5; Defective then warning enters case to be checked.
Second piston assembly assembling detection machine 4 and first piston assembly assembling detection machine 5 assemble detection simultaneously.Second piston assembly assembling detection machine 4 is identical with first piston assembly assembling detection machine 5 assembling characterization processes.
Second piston assembly assembling detection machine 4: assemble two leather cups of second piston, assembling is finished and is put into the detection frock, carries out vision-based detection, and whether the leather cup direction correct, qualified after, carry out return spring and press-fit; Defective, check whether the leather cup direction adorns mistake.Press-fit finish after, put into the fog lubrication frock, by the fog lubrication button, quantitatively fog lubrication is finished.Put into vacuum pressurize test fixture after fog lubrication is finished, press the vacuum test button, beginning is test automatically, qualified then workpiece next process, and defective then the warning enters the waste product circulation passage.Above operation must be carried out in strict accordance with order, then reports to the police as sequence error, can not assemble detection, has guaranteed the qualification rate and the reliability of product.
First piston assembly assembling detection machine 5: two leather cups of assembling first piston, assembling is finished and is put into the detection frock, carries out vision-based detection, whether the leather cup direction correct, qualified after, rivet, connecting rod press-fits, and press-fits automatically; Defective, check whether the leather cup direction adorns mistake.
Riveted joint press-fits: workpiece is put into frock, by beginning to press-fit button, clamp automatically, automatic riveting after finishing, enters connecting rod locking operation.Connecting rod locking: press start button, clamp automatically, cylinder body expands tight, uses the torque gun lock-screw, and moment of torsion is qualified, then enters the fog lubrication operation, and defective then the warning enters the waste product circulation passage.Fog lubrication: put into the fog lubrication frock, by the fog lubrication button, quantitatively fog lubrication is finished.Vacuum pressurize test: put into vacuum pressurize test fixture after fog lubrication is finished, press the vacuum test button, beginning is test automatically, the qualified next process that then enters, and defective then the warning enters the waste product circulation passage.Above operation must be carried out in strict accordance with order, then reports to the police as sequence error, can not assemble detection, has guaranteed the qualification rate and the reliability of product.
After 4 assemblings of second piston assembly assembling detection machine detect and finish, enter second piston cylinder body machine 6 of packing into.Workpiece enters frock, presses the both hands start button, and automatically clamping work pieces is pressed into cylinder body with piston automatically, and it is qualified to press-fit, and then can enter the first piston cylinder body machine 7 dress first pistons of packing into, defectively then reports to the police, and enters the waste product circulation passage.
After 5 assemblings of first piston assembly assembling detection machine detect and finish, enter the first piston cylinder body machine 7 of packing into, press the jump ring station.Workpiece enters frock, presses the both hands start button, and automatically clamping work pieces is pressed into cylinder body with piston automatically, and jump ring tightens automatically, and it is qualified to press-fit, and then can enter second piston cylinder body machine 6 of packing into and adorn second piston, defectively then reports to the police, and enters the waste product circulation passage.
After cylinder body has been adorned the first piston and second piston, enter exercise test machine 8 and test:
Total travel test: workpiece is put into frock, press " startup " button, (speed can be divided into 3 grades to drive unit with 2 millimeters of per seconds, use computer settings) speed advance, the power sensor is gathered the piston resistance in real time, when trying hard to become when reaching setting value, the distance that piston is at that time passed by is a total travel.According to the relation of power and displacement, draw out the input power-stroke characteristic curve that advances in the whole testing process and return, calculate initiating power, total travel power, total travel and release force.Show each curve and the numerical value measured, the bright and color warning of test passes or the corresponding indicator lamp of defective usefulness shows correlation values after test finishes on liquid crystal display.
Idle stroke and test: whether the measurer of configure dedicated detects fixture system correct, and adjust measuring air pressure.The test of total travel and ride comfort finish qualified after, master cylinder carries out the idle stroke test.By pneumatic button master cylinder is carried out clamping, liquid outlet connects source of the gas and sensor automatically.The idle stroke method of testing is divided two big classes: qualitative test method and quantitative measuring method.Which kind of method of testing is system can select just to use.This test is described with the qualitative test method.
The qualitative test method: as long as in the qualified stroke of null stroke, get two points that belong near bound in qualified, by judgement during from the oil outlet air inlet atmospheric pressure value of these two positions whether in prescribed limit.Respectively the oil-out of two powers feed air pressure make centre valve and compensate opening standard-sized sheet the pressure of state downstream for being 20KPa, be 30KPa under closing state.Promote piston with the speed of 0.5mm/s, make it reach 4mm place continuously, test or respectively the air pressure at 0.8mm and 2mm place be respectively P1, P2; P1=P opens, and P2=P closes, for qualified; Otherwise it is defective.
Behind the exercise test machine 8, enter two air tightness test machines 9 and detect:
Hyperbar detects:
The master cylinder assembly is packed on the positioning fixture, hand closed two oil-outs, and will measure that air inlet pipe is manual to be installed on two fuel inlet fittings or the liquid storage rim of a cup.With the propulsive mechanism of string heart adjustable cylinder as master cylinder piston.Press " startup " button, string heart adjustable cylinder promotes master cylinder piston and inwardly advances prescribed stroke (also can not advance, whether advance can by the touch screen setting), then, system feeds 10Mpa air pressure from two fuel inlet fittings of trend or liquid storage rim of a cup, closes stop valve, stable, after the pressurize, fall △ P with its pressure of vertical compression sensor measurement, the t value can be set within the specific limits, the standard value of △ P also can be set arbitrarily, measured value and standard value are relatively differentiated the acceptance or rejection sound and light alarm automatically.This special plane has disposed with workbench conjuncted, and the visual protective cover of sufficient intensity is arranged, and only after protective cover is shut, just can start the detection special plane and detect, and guarantees personal safety.
The high vacuum seal detection:
After finishing the hyperbar test item, system is evacuated to 300pa (P) from trend two fuel inlet fittings or liquid storage rim of a cup, and the P value can be passed through the accurate voltage regulating valve regulation, closes vaccum stop valve, stablized 5 seconds, after the pressurize 10 seconds (t), survey its pressure and fall △ P, the t value can be set within the specific limits, the standard value of △ P also can be set arbitrarily, measured value and standard value are relatively differentiated sound and light alarm automatically.
After two air tightness test machines 9 test, workpiece enters fuel inlet fitting and lubricating cup assembly machine 10, master cylinder is fixed on the anchor clamps, lubricating cup is put on the master cylinder assembly oil-in, and aligns, use pneumohydraulic pressure-cylinder that lubricating cup is pressed in the supply opening, if lubricating cup is to connect with bearing pin, then bearing pin is pressed in the hole, if screw connects, then with the screw in compression lubricating cup.
After fuel inlet fitting and lubricating cup assembly machine 10 operations are finished, enter sealing and return time test machine 11 detects:
Vacuum keeps back the zero-time:
Master cylinder is fixed on the anchor clamps, connects each joint, press " startup " button, the cylinder push rod, leather cup overcompensation hole, centre valve cuts out, and be evacuated down to the 300pa(absolute pressure) to two chamber oil-outs, close vaccum stop valve, make it stablize 5 seconds (t1) after, record its vacuum value P, again behind the elapsed time t2, detect its vacuum drop-out value △ P, it is whether qualified that measured value and standard value 200pa judge more automatically, differentiates color automatically and report to the police.Equipment shows the time dependent curve of two chamber vacuums, and shows t1, t2, p and △ p, t1, t2, and the bound standard value of p value can be adjustable within the specific limits according to product requirement.After finishing above-mentioned detection, return augmentor rapidly, make first piston freely be retracted into the home position, record the time t3 when augmentor begins to return to two chamber vacuums and drops to 0kpa separately, equipment shows the time dependent curve of two chamber vacuums, and the value of demonstration t3, the standard value of t3 can be set within the specific limits.
The low pressure air-tightness:
Cylinder piston and cup packing: piston-advance 5~10mm, closing center's valve and compensate opening advance 0.2MPa ± 0.02MPa air from liquid outlet, pressurize, behind the voltage stabilizing setting-up time, the comparative result with standard value 7kpa falls in the air pressure in the test 9s.Qualified green light is bright, and defective red light is bright.The fluid reservoir air-tightness: sealing fluid reservoir filling opening, advance to set air pressure from the master cylinder liquid outlet, after stablizing, the air pressure in the test stipulated time falls.And point out qualified and defective.
After sealing and return time test machine 11 are finished, workpiece dress dust cap workbench 12 dress dust caps.
After dress dust cap workbench 12 was finished, workpiece enters checked the 13 inspection packings of packing workbench.The assembling and the detection of automobile braking master cylinder are finished.
Assembling provided by the utility model, testing conditions and detection method satisfy the detection requirement of stipulating in QC/T 311-1999 " master cylinder technical conditions " standard.