WO2013131266A1 - 一种汽车板落料方法及系统 - Google Patents

一种汽车板落料方法及系统 Download PDF

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Publication number
WO2013131266A1
WO2013131266A1 PCT/CN2012/072087 CN2012072087W WO2013131266A1 WO 2013131266 A1 WO2013131266 A1 WO 2013131266A1 CN 2012072087 W CN2012072087 W CN 2012072087W WO 2013131266 A1 WO2013131266 A1 WO 2013131266A1
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WO
WIPO (PCT)
Prior art keywords
cutting
blanking
cut
robot
waste
Prior art date
Application number
PCT/CN2012/072087
Other languages
English (en)
French (fr)
Inventor
吴瑞珉
金文海
阎启
金成国
杨赛丹
王玉明
乔俊良
潘胜波
吕常青
Original Assignee
宝山钢铁股份有限公司
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by 宝山钢铁股份有限公司 filed Critical 宝山钢铁股份有限公司
Priority to KR1020137034040A priority Critical patent/KR20140007968A/ko
Priority to EP12870819.5A priority patent/EP2823932B1/en
Priority to JP2014525287A priority patent/JP5882464B2/ja
Priority to US14/130,375 priority patent/US9566677B2/en
Priority to PCT/CN2012/072087 priority patent/WO2013131266A1/zh
Publication of WO2013131266A1 publication Critical patent/WO2013131266A1/zh

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Classifications

    • 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
    • B23P23/00—Machines or arrangements of machines for performing specified combinations of different metal-working operations not covered by a single other subclass
    • B23P23/06—Metal-working plant comprising a number of associated machines or apparatus
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/08—Devices involving relative movement between laser beam and workpiece
    • B23K26/083—Devices involving movement of the workpiece in at least one axial direction
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/0093—Working by laser beam, e.g. welding, cutting or boring combined with mechanical machining or metal-working covered by other subclasses than B23K
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/08—Devices involving relative movement between laser beam and workpiece
    • B23K26/0869—Devices involving movement of the laser head in at least one axial direction
    • B23K26/0876—Devices involving movement of the laser head in at least one axial direction in at least two axial directions
    • B23K26/0884—Devices involving movement of the laser head in at least one axial direction in at least two axial directions in at least in three axial directions, e.g. manipulators, robots
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/36—Removing material
    • B23K26/38—Removing material by boring or cutting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/70—Auxiliary operations or equipment
    • B23K26/702—Auxiliary equipment
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
    • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
    • B25J11/00—Manipulators not otherwise provided for
    • B25J11/005—Manipulators for mechanical processing tasks
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B25—HAND TOOLS; PORTABLE POWER-DRIVEN TOOLS; MANIPULATORS
    • B25J—MANIPULATORS; CHAMBERS PROVIDED WITH MANIPULATION DEVICES
    • B25J11/00—Manipulators not otherwise provided for
    • B25J11/005—Manipulators for mechanical processing tasks
    • B25J11/0055—Cutting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
    • B65G57/00—Stacking of articles
    • B65G57/02—Stacking of articles by adding to the top of the stack
    • B65G57/03—Stacking of articles by adding to the top of the stack from above
    • B65G57/04—Stacking of articles by adding to the top of the stack from above by suction or magnetic devices
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2101/00—Articles made by soldering, welding or cutting
    • B23K2101/006—Vehicles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2101/00—Articles made by soldering, welding or cutting
    • B23K2101/18—Sheet panels
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S901/00—Robots
    • Y10S901/14—Arm movement, spatial
    • Y10S901/16—Cartesian, three degrees of freedom
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S901/00—Robots
    • Y10S901/30—End effector
    • Y10S901/40—Vacuum or mangetic
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49764—Method of mechanical manufacture with testing or indicating

Definitions

  • the invention relates to automobile manufacturing technology, in particular to an automobile panel blanking method and system. Background technique
  • the traditional automotive panel blanking adopts mold blanking, and its equipment consists of: conveying unit, press unit and stacking unit. Simple material shapes (such as rectangular, trapezoidal and curved) can be cut and cut, and the material of the complex curve is blanked by the mold.
  • the blanking line needs to be configured with different blanking dies according to the size of the material of the model, and different pieces can be produced by changing the mold.
  • the efficiency of the car blanking line is very high, ranging from 4 million pieces to 6 million pieces per year. Calculated at 3800 hours per year, the average is about 25 tablets per minute.
  • the sheet material is discharged, according to the number n of the laser cutting heads set, the single piece cutting line is divided into n parts according to the operation balance principle; when the strip enters the first cutting operation area, the first part of the line is cut Or a curve, such as a semicircle; when the strip enters the second cutting area, cuts the second part of the line or curve, such as the other half.
  • the round scrap falls onto the lower scrap strip; when the strip enters the third cutting work area, the third portion of the strip is cut or curved; the edge scrap falls onto the lower scrap strip; the strip enters the fourth cut In the work area, cut the fourth part of the line or curve of the sheet.
  • the edge scrap falls onto the lower scrap strip; after the strip passes the gripping drive roller, the fifth cutting head is cut transversely to cut the last joint between the flakes; the flakes enter the dip area and are stacked .
  • the sheet material is discharged; the group is cut and transported to the cutting station; the material enters the cutting area and stops; the two sets of conveying rollers are longitudinally adjusted to the shape of the cutting waste before and after the cutting station; the first area of the sheet After the cutting is completed, the waste falls into the waste conveyor belt; the strip advances to the second cutting area of the sheet and stops; Before and after the cutting position, the two sets of conveying rollers are longitudinally adjusted to the shape of the cutting waste; the second area of the sheet is cut, the waste falls into the scrap conveyor; the strip advances to the third cutting area of the sheet and stops; The group transfer rolls are longitudinally adjusted to the shape of the cutting waste; the third area of the sheet is cut, and the waste falls into the waste conveyor; after the individual sheets are cut, they enter the stacking area through the conveying device. The subsequent strips are also cut.
  • AIR LIQUILD proposed a waste blanking scheme for strip lateral support adjustment.
  • AUTOMATIC FEED and AIR LIQUILD jointly proposed a technical solution for stepping laser blanking.
  • the overall layout of AIR LIQUILD is adopted.
  • the waste treatment is based on the vertical adjustment of AUTOMATIC FEED.
  • the program uses three robots with a seventh axis to carry the package and finished chips and stack the chips. Five laser cutting units were set up, two of which were cuts in groups, and the other three were cuts in a single piece. In addition, there are two stations as buffer dumping stations.
  • the traditional pendulum cutting die blanking is a method of stepping and conveying the front end of the strip with no clamping and fixing.
  • the bottom of the strip is a wheeled support method, and a returning lock is used for the blanking operation.
  • the continuous strip feeding method proposed by AUTOMATIC FEED has a pinch roller at the front and rear ends of the blank cutting area, and the strip is fed continuously in this area at a set speed. There is a waste conveying device at the lower part of the strip, and the cut waste falls on the conveyor belt. The last knife is cut after the rear pinch roller.
  • Cutting operations that require dimensional and shape tolerances use a displacement control strategy that ensures the geometric accuracy of the cut shape.
  • the speed control strategy adopted by AUTOMATIC FEED for continuous blanking is based on the precise running speed of the pinch plate, and the cutting robot with the Cartesian coordinates performs the cutting operation at the set trajectory and speed.
  • the deviation of the pinch roller and its belt speed will cause errors in the shape of the cut, the slits cannot be docked, and the scrap cannot fall off. Since multiple cutting machines work at the same time, even with a belt speed measuring device (such as a laser speedometer), it is difficult to ensure the seaming of multiple equipment cutting operations.
  • the speed of the three equipments is the same.
  • the AUTOMATIC FEED solution requires the belt to feed the roller speed, and the two support plates with the needle conveyor belt at the same speed before and after the pinch roller. Otherwise, the needle support on the conveyor will scratch the board. band.
  • Needle-type support for the needle on the conveyor chain one is easy to cut, and the other is that the small scrap of cutting is easy to get stuck in the conveyor belt. On.
  • the solution has three sections of cutting area plus a cutting area after the pinch rolls, each area cutting different areas of the sheet.
  • the strip is in a tensioned state, but the lateral tension of the different sections of the strip varies greatly, and the shape of the strip is not guaranteed, which affects the quality of the cut.
  • the distance between the cutting head and the plate surface is 0.5mm ⁇ lmm.
  • the strips are conveyed by the pinch rolls at a distance of more than 10 m, and the deviation of the strips will result in batch waste for cutting operations. Therefore, the program must have a corrective centering device.
  • the cutting machine operation in the post-process needs to be docked with the slits of the previous process to ensure the scrap off. Due to the butt joint slitting during the movement of the strip, the movement of the pinch rolls and the progress of the Cartesian robot and the shape of the plate are very high, and the realized technology and equipment are costly.
  • the cutting device is a robot with a Cartesian coordinate of 3 degrees of freedom, due to the unidirectional movement of the strip, the cutting path of the web is difficult to achieve or requires a large amount of idle travel to ensure.
  • the sheet material of the automobile sheet is discharged, the shape and size of the material are determined according to the length of the sheet material, and the material is cut into a group; then, the material to be cut according to the material to be cut is used for the liner mold.
  • the lining die corresponding to the waste is hollowed out to form a blanking hole, and the size of the blanking hole is larger than the size of the actual cutting waste blanking; then, the material is placed on the lining die; the shape of the component is according to the shape of the automobile sheet Laser cutting, the scraped scrap is dropped onto the lower scrap conveyor through the blanking hole of the liner mold; the cut flakes are stacked.
  • the conveying robot transfers the component from the component conveying chain to the lining die of the cutting working unit; the cutting device of the cutting working unit performs the cutting operation of the sheet material, and the scraped scrap is removed from the lining die
  • the falling holes fall into the lower waste guide groove and slide down onto the waste conveyor belt; after the single piece of material is cut, the stacked pieces are separately stacked by the stacking robot.
  • the lining die is designed as a set of 4 pieces, or 6 sets according to the working length of the production line.
  • one conveying robot is arranged on each side of the conveying chain of the group, and two cutting working units are arranged on each side of the conveying robot; and a stacking robot is arranged on the side of each cutting working unit.
  • the handling robot uses a vacuum chuck to pick up and place the material.
  • the liner mold is directly cut and processed on the cutting work unit and positioned.
  • the automobile panel blanking system of the present invention comprises: a component conveying chain; at least one conveying robot disposed on one side of the group conveying chain; at least one cutting working unit located on one side of the conveying robot; and at least one cutting working unit A laser cutting machine; a stacking robot is arranged on the side of the cutting working unit; a lining die is arranged on the cutting working unit, and a corresponding blank is formed on the lining die to form a blanking hole, and the blanking hole size is larger than the actual cutting waste blanking Dimensions; a scrap chute is arranged in the lower part of the lining die of the cutting work unit, and a scrap conveyor belt is also arranged corresponding to the scrap chute.
  • a conveying robot is arranged on each side of the group conveying chain, and two cutting working units are arranged on each side of the conveying robot to form four cutting working units; each cutting working unit is provided with two laser cutting machines, each There are 2 stacking robots on the side of each cutting work unit.
  • the laser cutting machine is in the form of a rectangular coordinate robot, which can move in the longitudinal direction and the lateral direction, and the two laser cutting machines have a partial intersecting working area in the longitudinal direction.
  • the invention adopts the elimination method of laser cutting waste, which is different from the continuous and step blanking mode of AUTOMATIC FEED and AIR LIQUILD, and the sheet conveying chain does not need to carry waste or dynamically adjust the length of the telescopic material conveying chain, and it passes through the sheet lining.
  • the formwork is used for waste removal.
  • the invention adopts a single orthogonal coordinate robot to complete the cutting operation of the single piece of material, and avoids various problems caused by the seaming and cutting precision of the blanking scheme of AUTOMATIC FEED and AIR LIQUILD.
  • the invention has flexibility and independence, wherein the failure of a single set of cutting equipment does not affect the operation of the entire production line, and only the fault cutting device needs to be automatically or manually opened out of the cutting area.
  • FIG. 1 is a top plan view of an embodiment of an automotive panel blanking system of the present invention.
  • FIG. 2 is a perspective view of an embodiment of the present invention.
  • Figure 3 is a side view of Figure 2.
  • Figure 4 is a schematic view of a liner mold of the present invention. Detailed description of the invention
  • the automobile panel blanking system of the present invention comprises: a component conveying chain 1; two conveying robots 2, 3 are disposed on one side of the component conveying chain 1; and four cutting working units 5, 5 , 5", 5,,,,, located on the 2, 3 side of the handling robot; cutting work unit 5 (taking the cutting work unit 5 as an example, the other cutting work units are the same), setting two laser cutting machines 6, 6'; cutting The working unit 5 (taking the cutting working unit 5 as an example, the same below) is provided with two stacking robots 7, 7'; the lining die 8 is arranged on the cutting working unit 5, and the lining die 8 is hollowed out corresponding to the scrap.
  • the size of the blanking hole is larger than the size of the actual cutting waste blanking; the discharging forming forming material 4 is placed on the lining die 8 according to the sheet material; the lower part of the lining die 8 of the cutting working unit 5 is provided with waste The chute 9, the waste chute 9 is also provided with a waste conveyor belt 10.
  • the laser cutting machine 6, 6' is in the form of a Cartesian robot, which can move in the longitudinal direction and the lateral direction, and the two cutting machines 6, 6' have a partial intersecting working area in the longitudinal direction. According to the actual situation of the group materials in the group, the material is cut.
  • the GM automobile D06 rear door inner panel thin sheet material assembly material the assembly material 4 includes four sleeve material sheets 11 .
  • the lining die 8 is designed according to the arrangement of the four sleeve pieces 1 1 , and the lining die design is carried out according to the scraps to be cut off from the assembly, and the blanking holes 81 are formed on the lining die 8 corresponding to the waste.
  • the liner mold can be directly cut and positioned on the cutting unit.
  • the cut blanking holes need to be processed to facilitate blanking.
  • the size of the blanking hole is larger than the size of the actual cutting waste blanking.
  • the material is transported to the set position through the material conveying chain 1 for two handling robots 2, 3 to take the material.
  • Two handling robots 2, 3 According to the operation strategy, the materials are sequentially placed on the lining molds of the four cutting work units 5, 5, 5, 5, and positioned.
  • Handling robot 2, 3 use the vacuum suction cup method to pick up and place the material.
  • Each cutting work unit 5 comprises: a basic gantry of the cutting unit 51, a lining die 8, and two laser cutting machines in the form of right angle coordinate robots 6, 6'.
  • the laser cutting machine in the form of two Cartesian robots has a longitudinal working stroke covering two sheets of cutting area.
  • the two cutting machines have partially intersecting working areas in the longitudinal direction.
  • Each cutting unit is configured with a stacking unit.
  • Each stacking unit consists of two stacking robots and two clamps, four clamps or six clamps.
  • the stacking robot uses a vacuum chuck to pick up the way.
  • the stacking strategy is as follows: large parts can be stacked by one-piece vacuum picking; small pieces can be stacked by multiple picking, the position of the suction cup can be dynamically adjusted, and the stacking can be divided; the picking and stacking operation of the finished product is performed at the same time of cutting operation, ie The cutting robot can be picked up and stacked.
  • the handling robot 2 grabs the first component 4 from the assembly conveyor chain 1 and transports it to the liner module 8 of the cutting unit 5.
  • the laser cutting machine 6, 6' is on the two sides of the cutting base gantry 51 during the discharging; the laser cutting machine 6, 6' starts the cutting operation of the group according to the preset cutting strategy and the working trajectory; two laser cutting machines 6, 6' Working in the same direction, one starting from the end of the basic gantry and the other starting from the middle of the basic gantry.
  • the laser cutting machine 6 and 6' have a balanced amount of work.
  • the single piece of material is completed by a single laser cutting machine, and the edge of the welding is cut out once;
  • the handling robot 3 picks up the second component, transports it and places it on the lining die of the cutting work unit 5".
  • Cutting the working unit 5" Two laser cutting machines according to the preset The cutting strategy and the work track start the cutting operation of the group material;
  • the handling robot 2 picks up the third component, transports it and places it on the liner mold of the cutting work unit 5'.
  • the two laser cutting machines of the cutting work unit 5' start the cutting operation of the group according to the preset cutting strategy and the work track;
  • the handling robot 3 picks up the fourth component, transports it and places it on the cutting work unit 5, "the lining die.
  • the cutting work unit 5 the two cutting machines are based on Pre-setting the cutting strategy and the work track to start the cutting operation of the component;
  • the corresponding stacking robot such as the stacking robot 7, 7' corresponding to the cutting work unit 5, performs the picking and stacking operation.
  • the laser cutting machines 6, 6' are respectively operated to the two ends of the cutting base stage.
  • the handling robot 2 transports the fifth block to the cutting work unit 5 lining mold, and the laser cutting machine 6, 6' cutting machine starts the cutting operation.
  • the sixth block is transported to the cutting work unit 5"; the seventh block is transported to the cutting work unit 5'; the eighth block is transported to the cutting work unit 5,".
  • the invention adopts the cutting working unit arranged on both sides of the component conveying chain, and cooperates with the conveying robot and the stacking robot to make the whole production line flexible and independent, and the failure of the single cutting device does not affect the operation of the entire production line. , just need to open the cutting area automatically or manually by the fault cutting device.

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  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Optics & Photonics (AREA)
  • Mechanical Engineering (AREA)
  • Plasma & Fusion (AREA)
  • Robotics (AREA)
  • Laser Beam Processing (AREA)

Abstract

一种汽车板落料方法以及使用该方法的系统，该方法包括以下步骤：首先，对汽车板片料（11）进行排料，按片料（11）倍尺长度确定组料（4）形状、大小，并切割成组料（4）；接着，根据组料（4）需切除的废料进行衬板模（8）的设计，衬板模（8）上对应废料处镂空形成落料孔（81），落料孔（81）尺寸大于实际切割废料落料的尺寸；然后，将组料（4）放置至衬板模（8）上；对组料（4）按汽车板片料（11）的形状激光切割，切除的废料通过衬板模（8）的落料孔（81）落到下部的废料输送带（10）上；切割好的片料（11）进行堆垛作业。该汽车板落料方法可以有效地对切割废料进行处理，提高落料的效率。

Description

一种汽车板落料方法及系统 发明领域
本发明涉及汽车制造技术， 特别涉及一种汽车板落料方法及系统。 背景技术
传统的汽车板落料采用模具落料， 其设备组成包括： 输送单元、 压机单元 和堆垛单元。 简单的料片形状 （如长方形、 梯形及弧形） 可采用摆切方式， 复 杂曲线的料片采用模具落料。 落料线需要根据车型的料片大小形状配置不同的 落料模具， 通过更换模具生产不同的料片。
汽车板落料线作业效率非常高， 在 400万片 ~ 600万片 /每年。 按 3800小 时每年计算， 平均每分钟约为 25片。
随着大功率激光技术近年来的迅猛发展， 许多院所及厂商开始研究基于光 纤激光器用于汽车板落料技术。美国 AUTOMATIC FEED与法国 AIR LIDUILD 公司在公开信息发布了基于激光切割的汽车板落料技术。 美国 AUTOMATIC FEED 公司的技术方案基于激光技术提出二种落料模式： 一种带卷连续进给落 料， 一种是步进落料。
1、 板带连续进给落料：
对片料进行排料， 根据设置的激光切割头的数量 n, 根据作业均衡原则将 单件片料切割线分成 n份； 板带进入第一个切割作业区域时， 切割片料的第一 部分线段或曲线， 如半圓； 板带进入第二个切割作业区域时， 切割片料的第二 部分线段或曲线， 如另半个圓。 圓废料落到下部的废料带上； 板带进入第三个 切割作业区域时， 切割片料的第三部分线段或曲线； 边部废料落到下部的废料 带上； 板带进入第四个切割作业区域时， 切割片料的第四部分线段或曲线。 边 部废料落到下部的废料带上；板带通过夹持驱动辊后， 第五台切割头横向切割， 使片料之间的最后连接部分切开； 片料进入垛料区域， 并堆垛。
2、 步进落料：
对片料进行排料； 成组切料， 并运送至切割工位； 组料进入切割区域， 并 停止； 切割工位前后二组传送辊纵向调整至切割废料形状； 片料的第一个区域 切割完成， 废料落入废料传送带； 板带前进至片料的第二切割区域并停止； 切 割工位前后二组传送辊纵向调整至切割废料形状； 片料的第二个区域切割完 成， 废料落入废料传送带； 板带前进至片料的第三切割区域并停止； 切割工位 前后二组传送辊纵向调整至切割废料形状； 片料的第三个区域切割完成， 废料 落入废料传送带； 单各片料切割完成后， 通过输送装置进入堆垛区域。 后续板 带同样切割。
另外， AIR LIQUILD公司提出了一种板带横向支撑调整的废料落料方案。 AUTOMATIC FEED公司与 AIR LIQUILD公司二家联合提出了一种步进 激光落料的技术方案， 总体采用 AIR LIQUILD公司布置方案， 废料处理采用 AUTOMATIC FEED公司的纵向调整方案。 该方案采用带第七轴的 3台机器人 搬运成组料和成品料片、 并堆垛料片。 设置 5台激光切割单元， 其中二台为成 组片的切割， 另三台为单片料分区域的切割。 此外还有二个工位作为緩冲倒料 工位。
传统摆剪模落料为板带前端无夹持固定， 后端夹棍步进输送的作业方式。 板带底部为轮式支撑方式， 落料作业时采用回程止锁装置。
AUTOMATIC FEED公司提出的连续落料的板带输送方式， 在落料切割区 域前后端有夹送辊， 板带按设定速度在该区域连续进给。 板带下部有废料输送 装置， 切割的废料落到传送带上。 最后一刀切断在后端夹送辊之后。
该送料方式的技术难点有下面几个方面：
1. 基于速度控制策略的形状切割
对尺寸与形状误差有要求的切割作业采用的是位移控制策略， 这样能确保 切割形状的几何精度要求。 AUTOMATIC FEED的连续落料采用的速度控制策 略， 其基于夹送板带运行速度精准， 直角坐标的切割机器人按设定的轨迹及速 度进行切割作业。 夹送辊及其板带速度的偏差将带来切割形状的误差， 切缝无 法对接，废料不能脱落。 由于多台切割机同时作业， 即使采用板带测速装置（如 激光测速仪） ， 也比较难确保多台设备切割作业的切缝对接。
2. 三台设备线速度相同， AUTOMATIC FEED 的方案要求板带夹送辊速 度、 夹送辊前后二台支撑板带针式循环传送带按同样速度运行， 否则传送带上 的针式支撑会划伤板带。
3. 针式支撑输送链上的针， 一是易切坏， 二是切割的小废料易卡在输送带 上。
4. 切割区域的板形无法保证
连续送料与切割时， 板带在切割区域的状态。 该方案有三段切割区域加上 夹送辊之后的切断区域， 各区域切割片料的不同区域。 板带处于有夹送有张力 的状态， 但板带不同区段的横向张力差异很大， 板形无法保证， 影响切割的质 量。 切割作业时， 切割头与板面距离 0.5mm~lmm。
5. 后夹送辊过料困难
连续送料与切割时， 板料过后夹送辊时， 不仅容易拉伤夹送辊， 而且会导 致卡料甚至断带。
6. 板带走偏对形状切割的影响
板带通过夹送辊输送， 且间距在 10m以上， 板带的走偏将导致切割作业的 批量废品。 所以该方案必须有纠偏对中装置。
7. 切缝对接精度要求高
由于料片为多套切割机在不同区域中切割完成， 所以后工序的切割机作业 需要与前工序的切缝对接， 以确保废料脱落。 由于在板带移动过程对接切缝， 对夹送辊运动与直角坐标机器人运动进度以及板形提出非常高的要求， 实现的 技术与设备代价很高。
8. 相对运动情况下的片料切割轨迹
虽然切割设备为直角坐标 3 自由度的机器人， 但由于板带单方向运动， 料 片切割轨迹难于实现或需要大量的空行程来保证。
9. 单台切割机故障会导致产线停产
由于采用了多套切割机对同一片料不同区域进行切割的策略， 当其中一台 切割设备故障时会影响整条产线的作业。 如需在单套切割机故障时完成产线的 切割作业， 必须采用复杂的切割控制策略及硬件技术来实现异常情况下的切割 作业。
AUTOMATIC FEED公司与 AIR LIQUILD公司联合提出的汽车板激光步 进落料方案较 AUTOMATIC FEED公司提出的连续落料方案的技术可行性强很 多。 该步进落料的技术难点在于废料的落料及产线单位时间产量。 发明概述
本发明的目的在于提供一种汽车板落料方法及系统， 可以有效地对切割废 料处理， 提高落料的效率。
为达到上述目的， 本发明的技术方案是：
汽车板落料方法， 首先， 对汽车板片料进行排料， 按片料倍尺长度确定组 料形状、 大小， 并切割成组料； 接着， 根据组料需切除的废料进行衬板模的设 计， 衬板模上对应废料处镂空形成落料孔， 落料孔尺寸大于实际切割废料落料 的尺寸； 然后， 将组料放置至衬板模上； 对组料按汽车板片料的形状激光切割， 切除的废料通过衬板模的落料孔落到下部的废料输送带上； 切割好的片料进行 堆垛作业。
进一步， 组料切割后， 由搬运机器人将组料从组料输送链上搬运至切割工 作单元的衬板模上； 切割工作单元的切割设备进行片料的切割作业， 切除的废 料从衬板模的落料孔中落到下部废料导槽， 并滑落到废料运输带上； 在单片料 切割完成后， 由堆垛机器人分别对切割好的片料进行堆垛作业。
另外， 衬板模设计为 4片片料一组， 或根据产线的作业长度设计为 6片一 组。
又， 组料输送链两侧各一台搬运机器人， 搬运机器人两侧各设两个切割工 作单元； 各切割工作单元的侧边设堆垛机器人。
所述的搬运机器人采用真空吸盘方式进行拾取和放置组料。
所述的衬板模直接在切割工作单元上切割加工， 并定位。
本发明的汽车板落料系统， 其包括， 组料输送链； 至少一台搬运机器人， 设置于组料输送链一侧； 至少一切割工作单元， 位于搬运机器人一侧； 切割工 作单元设至少一台激光切割机； 切割工作单元的侧边设堆垛机器人； 衬板模， 设置于切割工作单元， 衬板模上对应废料处镂空形成落料孔， 落料孔尺寸大于 实际切割废料落料的尺寸； 切割工作单元的衬板模下部设置有废料溜槽， 对应 废料溜槽还设废料输送带。
进一步， 所述的组料输送链两侧各设一台搬运机器人， 搬运机器人两侧各 设两个切割工作单元， 形成 4个切割工作单元； 每个切割工作单元设二台激光 切割机， 每个切割工作单元的侧边设 2台堆垛机器人。 所述的激光切割机为直角坐标机器人形式， 可沿纵向、 横向运动， 二台激 光切割机在纵向有部分交叉工作区域。
本发明的优点在于：
本发明采用激光切割废料的剔除方式，不同于 AUTOMATIC FEED 和 AIR LIQUILD公司的连续和步进落料方式， 片料输送链无需携带废料或不用动态调 整伸缩接料输送链长度， 其通过片料衬板模进行废料去除。 本发明采用单台直 角坐标机器人完成单片料的切割作业， 避免了 AUTOMATIC FEED 和 AIR LIQUILD公司落料方案的切缝对接与切割精度带来的各种问题。
本发明具灵活性和独立性， 其中单套切割设备的故障不影响整条产线的作 业， 仅需将故障切割设备自动或手动开出切割区域即可。 附图说明
图 1为本发明汽车板落料系统一实施例的俯视图。
图 2为本发明一实施例的立体示意图。
图 3为图 2的侧视图。
图 4为本发明衬板模的示意图。 发明的详细说明
参见图 1〜图 4, 本发明的一个实施例。 在本实施例中， 本发明的汽车板落 料系统， 其包括， 组料输送链 1 ; 两台搬运机器人 2、 3 , 设置于组料输送链 1 一侧； 四个切割工作单元 5、 5，、 5"、 5，，，， 位于搬运机器人 2、 3—侧； 切割工 作单元 5 (以切割工作单元 5为例， 其他切割工作单元相同） 设两台激光切割 机 6、 6' ； 切割工作单元 5 (以切割工作单元 5为例， 下同） 的侧边设 2台堆 垛机器人 7、 7' ； 衬板模 8 , 设置于切割工作单元 5 , 衬板模 8上对应废料处 镂空形成落料孔 81 , 落料孔尺寸大于实际切割废料落料的尺寸； 按片料进行排 料形成组料 4放置于衬板模 8上； 切割工作单元 5的衬板模 8下部设置有废料 溜槽 9, 对应废料溜槽 9还设废料输送带 10。
所述的激光切割机 6、 6' 为直角坐标机器人形式， 可沿纵向、 横向运动， 二台切割机 6、 6' 在纵向有部分交叉工作区域。 按片料成组排料实际情况， 切割组料。 本实施例中为通用汽车 D06后门内 板薄板片料组料情况， 该组料 4含四块套接片料 1 1。
衬板模 8按四张套接片料 1 1 的排布进行设计， 根据组料需切除的废料进 行衬板模的设计， 衬板模 8上对应废料处镂空形成落料孔 81。 该衬板模可直接 在切割单元上切割加工， 并定位。 切割完的落料孔需要进行处理， 便于落料。 落料孔尺寸大于实际切割废料落料的尺寸。
组料通过组料输送链 1运送至设定位置， 供两台搬运机器人 2、 3取料。 两台搬运机器人 2、 3根据作业策略依次取料分别放置到四个切割工作单元 5、 5，、 5"、 5，"的衬板模上并定位。
搬运机器人 2、 3采用真空吸盘方式进行拾取和放置组料。
每个切割工作单元 5包括： 切割单元的基础台架 51、 衬板模 8、 二台直角 坐标机器人形式的激光切割机 6、 6' 。
二台直角坐标机器人形式的激光切割机作业纵向工作行程覆盖二张片料 切割区域。 二台切割机在纵向有部分交叉工作区域。
每个切割工作单元配置一套堆垛单元。 每个堆垛单元包括二台堆垛机器人 和二个垛位、 四个垛位或六个垛位。 堆垛机器人采用真空吸盘拾取方式。 堆垛 策略为： 大件可采用单件真空拾取堆垛； 小件采用多件拾取堆垛方式， 吸盘位 置可动态调整， 并分垛堆料； 切割作业的同时进行成品拾取堆垛作业， 即切割 完成机器人就可拾取并堆垛。
激光切割落料的作业流程如下：
搬运机器人 2从组料输送链 1抓取第一块组料 4 , 运送并放置到切割工作 单元 5的衬板模 8上。 放料时激光切割机 6、 6' 在切割基础台架 51的二侧； 激光切割机 6、 6' 根据预设定切割策略及作业轨迹开始组料的切割作业； 二台激光切割机 6、 6' 同方向作业， 一台从基础台架的端部开始， 另一台从基 础台架的中部开始。 激光切割机 6、 6' 作业量均衡， 单块片料由单台激光切割 机完成， 拼焊边一次走刀切出；
第二块组料到达搬运机器人拾取位后， 搬运机器人 3拾取第二块组料， 运 送并放置到切割工作单元 5" 的衬板模上。 切割工作单元 5" 二台激光切割机 根据预设定切割策略及作业轨迹开始组料的切割作业； 第三块组料到达搬运机器人拾取位后， 搬运机器人 2拾取第三块组料， 运 送并放置到切割工作单元 5' 的衬板模上。 切割工作单元 5' 的二台激光切割 机根据预设定切割策略及作业轨迹开始组料的切割作业；
第四块组料到达搬运机器人拾取位后， 搬运机器人 3拾取第四块组料， 运 送并放置到切割工作单元 5，"的衬板模上。 切割工作单元 5，"的二台切割机根据 预设定切割策略及作业轨迹开始组料的切割作业；
各切割工作单元在单张片料或多张片料切割完成后， 相应的堆垛机器人如 对应切割工作单元 5的堆垛机器人 7、 7' 进行拾取堆垛作业。
当切割工作单元 5切割作业与堆垛作业完成后， 激光切割机 6、 6' 分别运 行至切割基础台架的二端。 搬运机器人 2将第五块组料运至切割工作单元 5衬 板模上， 激光切割机 6、 6' 切割机开始切割作业。
如此循环往复， 第六块组料运至切割工作单元 5 " ； 第七块组料运至切割 工作单元 5' ； 第八块组料运至切割工作单元 5，"。
本发明由于采用组料输送链两侧布置切割工作单元， 并配合搬运机器人、 堆垛机器人， 使整条产线具灵活性和独立性， 单套切割设备的故障不影响整条 产线的作业， 仅需将故障切割设备自动或手动开出切割区域即可。

Claims

权 利 要 求 书
1. 汽车板落料方法， 首先， 对汽车板片料进行排料， 按片料倍尺长度确定 组料形状、 大小， 并切割成组料； 接着， 根据组料需切除的废料进行衬板模的 设计， 衬板模上对应废料处镂空形成落料孔， 落料孔尺寸大于实际切割废料落 料的尺寸； 然后， 将组料放置至衬板模上； 对组料按汽车板片料的形状激光切 割， 切除的废料通过衬板模的落料孔落到下部的废料输送带上； 切割好的片料 进行堆垛作业。
2. 如权利要求 1所述的汽车板落料方法， 其特征是， 组料切割后， 由搬运 机器人将组料从组料输送链上搬运至切割工作单元的衬板模上； 切割工作单元 的切割设备进行片料的切割作业， 切除的废料从衬板模的落料孔中落到下部废 料导槽， 并滑落到废料运输带上； 在单片料切割完成后， 由堆垛机器人分别对 切割好的片料进行堆垛作业。
3. 如权利要求 1或 2所述的汽车板落料方法， 其特征是， 衬板模设计为 4 片片料一组， 或根据产线的作业长度设计为 6片一组。
4. 如权利要求 2所述的汽车板落料方法， 其特征是， 组料输送链两侧各一 台搬运机器人， 搬运机器人两侧各设两个切割工作单元； 各切割工作单元的侧 边设堆垛机器人。
5. 如权利要求 1或 2或 4所述的汽车板落料方法， 其特征是， 所述的搬运 机器人采用真空吸盘方式进行拾取和放置组料。
6. 如权利要求 1或 2所述的汽车板落料方法， 其特征是， 所述的衬板模直 接在切割工作单元上切割加工， 并定位。
7. 汽车板落料系统， 其特征是， 包括，
组料输送链； 至少一台搬运机器人， 设置于组料输送链一侧；
至少一切割工作单元， 位于搬运机器人一侧； 切割工作单元设至少一台激 光切割机； 切割工作单元的侧边设堆垛机器人；
衬板模， 设置于切割工作单元， 衬板模上对应废料处镂空形成落料孔， 落 料孔尺寸大于实际切割废料落料的尺寸；
切割工作单元的衬板模下部设置有废料溜槽， 对应废料溜槽还设废料输送 带。
8. 如权利要求 7所述的汽车板落料系统， 其特征是， 所述的组料输送链两 侧各设一台搬运机器人， 搬运机器人两侧各设两个切割工作单元， 形成 4个切 割工作单元； 每个切割工作单元设二台激光切割机， 每个切割工作单元的侧边 设 2台堆垛机器人。
9. 如权利要求 7或 8所述的汽车板落料系统， 其特征是， 所述的激光切割 机为直角坐标机器人形式。
10. 如权利要求 8所述的汽车板落料系统， 其特征是， 所述的激光切割机 为直角坐标机器人形式， 可沿纵向、 横向运动， 二台激光切割机在纵向有部分 交叉工作区域。
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