WO2019218648A1 - 一种带竖直调节架的搓丝机和方法 - Google Patents
一种带竖直调节架的搓丝机和方法 Download PDFInfo
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- WO2019218648A1 WO2019218648A1 PCT/CN2018/119477 CN2018119477W WO2019218648A1 WO 2019218648 A1 WO2019218648 A1 WO 2019218648A1 CN 2018119477 W CN2018119477 W CN 2018119477W WO 2019218648 A1 WO2019218648 A1 WO 2019218648A1
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- reeling
- thread rolling
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21H—MAKING PARTICULAR METAL OBJECTS BY ROLLING, e.g. SCREWS, WHEELS, RINGS, BARRELS, BALLS
- B21H3/00—Making helical bodies or bodies having parts of helical shape
- B21H3/02—Making helical bodies or bodies having parts of helical shape external screw-threads ; Making dies for thread rolling
- B21H3/06—Making by means of profiled members other than rolls, e.g. reciprocating flat dies or jaws, moved longitudinally or curvilinearly with respect to each other
Definitions
- the invention relates to a thread rolling machine and a method with a vertical adjusting frame, which is a mechanical processing equipment and method, and is a thread processing equipment and method.
- the reeling plate is usually fixed to the bed or the sliding pallet by a press plate.
- This structure is simple and reliable, the process of the tooth (adjusting the relative position of the two pieces of the silk plate) is very fine and cumbersome, and the operator needs to repeatedly adjust the vertical position (perpendicular to the direction of the wire) of the wire plate and the lateral direction (and The direction of the silk is the same).
- the vertical position of the silk plate usually needs to be achieved by grinding the bottom of the wire plate (to remove a small amount of height) or by padding the bottom of the wire plate (minimizing the height of the wire plate), while the horizontal position of the wire plate is required Loosen the platen bolts and move the wire plate back and forth in a small amount to achieve the purpose of adjustment.
- the adjustment process of the silk plate consumes a lot of auxiliary time, and even a skilled operator takes ten minutes to complete. How to speed up the adjustment and achieve automation is a problem faced by the modern silk industry.
- the present invention proposes a reeling machine and method with a vertical adjustment frame.
- the wire reeling machine and method provide a vertical adjustment frame that can be adjusted up and down between the fixed reeling plate and the bed body, which facilitates the adjustment of the fixed reeling plate.
- a reeling machine with a vertical adjustment frame comprising: a bed body mounted with a sliding reeling plate, the bed body being provided with a truss frame fixed by bolts, said The raft frame is provided with a vertical groove perpendicular to the direction of the crepe, and the vertical groove is connected with a vertical adjustment frame with a vertical wedge matched with the vertical groove by a locking bolt, and the vertical adjustment frame is arranged There is a transverse groove which is connected to the fixed core plate by a locking bolt.
- the vertical adjustment frame is provided with a lateral fine adjustment bolt.
- the vertical wedge is provided with a vertical fine adjustment bolt.
- the vertical wedge and the vertical groove are a dovetail wedge and a dovetail groove.
- At least one pressure sensor is disposed between the dovetail wedge and the dovetail slot.
- an automatic discharge distributor is installed on the bed.
- the pressure sensor is connected to a pressure controller capable of recording and displaying a pressure value, and the pressure controller is connected to an automatic discharge distributor and a start-stop controller of the thread rolling machine.
- the pressure controller is one of a PLC, an industrial control computer, and a single chip microcomputer.
- a method of twisting the yarn using the above-mentioned twisting machine the steps of the method are as follows:
- Steps for installing and adjusting the reeling plate insert the fixed reeling plate into the transverse groove of the vertical adjustment frame, adjust the lateral position of the reeling plate through the transverse groove, and adjust the vertical position of the reeling plate through the dovetail wedge and dovetail groove , the position of the fixed reeling plate and the sliding reeling plate are matched to produce a qualified workpiece;
- Pre-machining steps adjust the vertical locking bolts to make the pressure sensor pre-tightening; use a batch of uniform material to carry out the twisting process, adjust the thread rolling machine and the silking board to meet the quality standards, and record each reaching the quality standard.
- the step of setting the pressure range setting the upper and lower limits of the upper and lower ranges of the pressure mean as the basis for normal processing;
- Processing steps sudden pressure abnormality occurs during the process, exceeding the upper or lower pressure limit, indicating that the machining abnormality is stopped; or after a period of processing operation, the pressure is gradually reduced to the lower pressure limit, indicating that the wire is worn out.
- the processing step when the pressure exceeds the upper limit or the lower limit, the parts with abnormal pressure are separated, and the next workpiece is alarmed and continues to be processed. If the pressure continues to be abnormal, the machine stops, and if the pressure abnormally disappears, the processing continues. Process, but keep the alarm.
- the invention has the beneficial effects that: the invention adds a vertical adjusting frame between the fixed reeling plate and the sill plate frame, so that the fixed reeling plate can be moved up and down, left and right, and fixed by a locking bolt, and an adjusting bolt can also be provided.
- the fine adjustment of the displacement makes the whole process of the squeegee to the tooth very easy and fast, greatly reducing the auxiliary time and improving the production efficiency.
- the pressure sensor can be set to obtain the pressure data of the twisting process, and it is an important basis for the quality control of the tanning.
- FIG. 1 is a schematic structural view of a thread rolling machine according to Embodiment 1 of the present invention.
- FIG. 2 is a schematic structural view of the thread rolling machine according to the first embodiment of the present invention, which is an enlarged view of the direction A in FIG. 1;
- FIG. 3 is a schematic structural view of a vertical adjustment frame according to Embodiment 1 of the present invention.
- Embodiment 1 is a diagrammatic representation of Embodiment 1:
- This embodiment is a reeling machine with a vertical adjustment frame, as shown in Figures 1, 2 and 3.
- the embodiment includes: a bed 2 on which a sliding skein plate 1 is mounted, the bed body is provided with a sill frame 3 fixed by bolts, and the sill plate frame is provided with a vertical groove perpendicular to the direction of the filature
- the vertical groove is connected by a locking bolt 4 to a vertical adjusting frame 5 with a vertical wedge 501 matched with a vertical groove, and the vertical adjusting frame is provided with a transverse groove 502, and the horizontal groove is locked
- the tightening bolt 6 is connected to the fixed twisting plate 7.
- the sliding reeling plate is mounted on the sliding pallet 9 by the pressing plate and the locking bolt 8, and reciprocates under the driving of the power, and the outer circular surface of the workpiece is processed while the workpiece 10 is moved.
- This embodiment adopts this conventional mounting method.
- the focus of this embodiment is on the way in which the fixed reeling plate is mounted.
- the fixed reeling board is connected to the bed body through the raft frame.
- a vertical adjusting frame is added on the basis of the truss frame, that is, the fixed reeling plate is connected with the vertical adjusting frame, and the vertical adjustment is performed.
- the frame is connected to the raft frame, and the raft frame is connected to the bed.
- the significance of the vertical adjustment frame is that it is convenient to fine-tune the vertical position of the fixed silk plate so that the teeth can be replaced when the wire is replaced.
- the traditional fixed silk plate is installed in the horizontal groove of the raft frame, so the sill frame is commonly known as the slab.
- the fixed reeling plate is fixed in the clamshell box by the pressing plate and the screw. By loosening the pressing plate and the bolt, the fixed reeling plate can be conveniently moved laterally, that is, the position of the reeling plate is laterally adjusted to perform the tooth alignment. It is a very fine work for the teeth.
- the present embodiment provides vertical grooves and vertical wedges, through the vertical grooves and vertical
- the engagement of the wedges forms an adjustment mechanism that is vertically up and down.
- a lateral groove is adopted, and one end of the lateral groove can be designed to be closed, so that a lateral fine adjustment bolt is arranged at the closed end to finely adjust the lateral position of the fixed wire plate.
- the vertical groove can also be designed to be closed at one end, and a vertical fine-tuning bolt is arranged to finely adjust the lateral position of the fixed silk plate.
- Vertical wedges and vertical grooves can be designed as rectangular wedges and rectangular grooves, or dovetail wedges and dovetail slots.
- At least one pressure sensor may be disposed between the vertical wedge and the vertical groove to detect the pressure of the wire, and the change of the pressure value of the wire is used to judge whether the process of twisting is correct. If the pressure value is found to be abnormal, the workpiece with abnormal pressure value can be discharged through the discharge distributor. If the pressure value is abnormally found, the machine is stopped and alarmed, thereby producing the effect of monitoring the production quality online.
- an automatic discharge distributor and a pressure controller matched with the pressure sensor can be provided on the bed. Since the control process is very simple, the pressure controller can be a simple control device such as a PLC or a single chip microcomputer, or a complicated industrial computer. Complex process control can be performed using complex industrial computer, such as accurate detection and calculation of pressure values, and setting multiple control thresholds to control the change of pressure values in multiple levels.
- Embodiment 2 is a diagrammatic representation of Embodiment 1:
- the embodiment is a modification of the first embodiment and is a refinement of the vertical adjustment frame in the first embodiment.
- the vertical adjustment frame described in this embodiment is provided with a lateral fine adjustment bolt 11, as shown in FIG.
- the lateral fine adjustment bolt described in this embodiment is a displacement for adjusting the lateral position of the silk reeling plate, and the displacement of the lateral position refers to a displacement direction that coincides with the moving direction of the sliding reeling plate.
- Embodiment 3 is a diagrammatic representation of Embodiment 3
- This embodiment is a refinement of the above embodiment, and is a refinement of the vertical wedge in the above embodiment.
- the vertical wedge described in this embodiment is provided with vertical fine adjustment bolts 12, as shown in Figs.
- a threaded adjusting hole 504 is disposed in the vertical wedge of the vertical adjusting frame. As shown in FIG. 3, the adjusting bolt passes through the vertical wedge, and the adjusting bolt top is on the side wall of the closed end of the vertical groove, and is rotated by the bolt. Drive the vertical adjustment frame to move vertically (up and down).
- the so-called vertical displacement in this embodiment means a direction of displacement perpendicular to the moving direction of the sliding reeling plate.
- Embodiment 4 is a diagrammatic representation of Embodiment 4:
- This embodiment is a refinement of the above embodiment, and is a refinement of the vertical wedge and the vertical groove in the above embodiment.
- the vertical wedges and vertical grooves described in this embodiment are dovetail wedges and dovetail slots, as shown in Figures 2 and 3.
- the combination of the dovetail groove and the dovetail wedge can be used in two ways. One is the combination of the shoulders on both sides, and the wedge top is separated, and the other is the groove bottom and the wedge top are combined. , while the shoulders on both sides are separated.
- the pressure sensor is arranged at the bottom of the groove, and the wedge shape of the dovetail groove is used, and the bolt is locked by the side. It delivers uniform pressure while providing a uniform preload. This is the key to this embodiment.
- Embodiment 5 is a diagrammatic representation of Embodiment 5:
- This embodiment is a refinement of the above embodiment, and is a refinement of the above-described embodiments with respect to the dovetail wedge and the dovetail groove.
- At least one pressure sensor is disposed between the dovetail wedge and the dovetail slot in this embodiment.
- Pressure sensors are a very common type of sensing element, and there are many types: strain gauge, piezoelectric, and semiconductor pressure sensitive. This embodiment can employ various pressure sensors that are commercially available.
- a pressure sensor can be arranged at the center of the wire plate. If the wire plate is large, the number of sensors can be appropriately increased, and the purpose is to detect the overall pressure of the wire plate as uniformly as possible. .
- one to four pressure sensors can be placed at the bottom of the dovetail slot to accurately sense the pressure changes experienced by the dowel plate.
- a sensor can be used to obtain uniform pressure under the action of the dovetail wedge.
- Pressure sensors can be installed in a variety of ways, depending on the sensor, such as slotting or opening the bed, fixing the pressure sensor, or setting a vertical adjustment bracket fixedly connected to the wire plate, the pressure sensor Installed on a vertical adjustment frame.
- This embodiment is a refinement of the above embodiment, and is a refinement of the discharge of the above embodiment.
- the automatic discharge distributor is also installed on the bed body of the embodiment.
- the function of the automatic discharge distributor is to separate the workpiece with too much or too little pressure on the core plate during processing.
- the distributor can use a simple electromagnetic distributor.
- This embodiment is a refinement of the above embodiment, and is a refinement of the controller in the above embodiment.
- the pressure sensor of this embodiment is connected to a pressure controller capable of recording and displaying a pressure value, and the pressure controller is connected to an automatic discharge distributor and a start-stop controller of the thread rolling machine.
- the pressure controller can be a simple switch controller, that is, when the pressure reaches a certain value, a signal is sent, and by using this signal to turn off the power of the thread rolling machine, the quality of the automatic control can be achieved.
- Some pressure sensors have threshold settings that can be used directly to control the switch without having to set up a dedicated controller. If it is more complicated, you can use a simple program controller. When a workpiece with abnormal pressure appears, start the automatic discharge distributor and separate the workpiece. When the subsequent workpiece contact pressure is abnormal, it will automatically stop and alarm. .
- Such control can use mature program controllers such as PLCs, microcontrollers, and the like. If you want to achieve more complex control, such as the average calculation of the measured values of multiple pressure sensors, or set up a database of measured values, and analyze the measured values by artificial intelligence to determine the processing situation, which requires the use of a relatively complex system of industrial computer .
- This embodiment is a refinement of the above embodiment, and is a refinement of the controller in the above embodiment.
- the pressure controller described in this embodiment is one of a PLC, an industrial control computer, and a single chip microcomputer.
- Embedded systems such as MUCs, system-on-chips, etc. can also be used to implement flexible processing systems by connecting networks.
- This embodiment is a twisting method using the above-described twisting machine.
- Filament processing is a highly automated and large-scale mass production method. Because it is a large number of large-scale production, it is hoped that human intervention in the production process can be minimized, or automation can be achieved as much as possible. Automated production requires automated processing and automated testing to ensure product quality. Filament processing is a very consistent process that generally guarantees processing quality. Despite the consistency of the production of silk, there are some special cases that lead to the appearance of defective products. For example: the workpiece enters the processing station incorrectly (causing a chaotic tooth), the shaped workpiece is mixed in (increased or reduced diameter), the two workpieces enter the processing station at the same time (the feed mechanism malfunctions), the workpiece itself Uneven materials, etc., will produce sudden changes in the quality of the workpiece during processing.
- thread inspection is a relatively complicated inspection process. It takes a lot of different instruments to detect the thread, how to perform fast online inspection, and what kind of detection method is used for online inspection, which is a problem in the industry.
- the existing method can only perform sampling inspection on products with higher requirements, that is, sample evaluation of one batch of products, and only the quality evaluation of the batch of products is obtained. This type of inspection is good for the production of this consistency in the production of silk, but if there are individual defects in the batch, there is usually no way. It seems that how to carry out online automatic detection in the process of silk reeling to control the quality of silk is a very difficult problem, and there is no way to deal with it in the industry for many years. Even today, in the tide of mechatronics, no effective method has been proposed.
- This embodiment is a method for online detection of silk.
- the basic idea of the method is to use a pressure sensor to detect the pressure of the wire, and to alarm or stop when a pressure abnormality occurs. Or determine the degree of wear of the silk plate by detecting the pressure change, so as to replace the wire plate in time.
- the embodiment fully utilizes the advantage of good consistency of the silk production process, and detects the pressure of the silk plate during the processing. If the pressure is uniform, the production process is normal, and if a pressure abnormality occurs, the warning is stopped by the shutdown, so that The operator performs inspection and maintenance.
- Pressure detection is a very common means of detection, displaying and recording pressure data, as well as controlling downtime are very mature control methods.
- the invention utilizes these mature technologies and ingeniously applies to the quality control of the silk reeling, solves the problem of on-line detection in the production of the reeling wire, enables the accidental damage to be controlled, and at the same time and under what circumstances, the replacement of the reeling plate has A clear indicator, the pressure indicator, has a more scientific basis for replacing the silk plate. What's even more interesting is that through this pressure detection, it is also possible to control the quality difference of batch workpieces caused by the replacement of the core plate, which is a problem that has not been solved in the industry for a long time.
- Steps of installing and adjusting the twisting plate insert the fixed twisting plate into the transverse groove of the vertical adjusting frame, adjust the lateral position of the fixed silk plate through the transverse groove, and adjust the twisting plate through the dovetail wedge and the dovetail groove.
- the vertical position allows the position of the fixed reeling plate and the sliding reeling plate to match and produce a qualified workpiece.
- Pre-machining step Adjust the vertical locking bolt to subject the pressure sensor to the pre-tightening force. Use a batch of uniform material to carry out the processing of the thread, adjust the thread rolling machine and the core board to meet the quality standards, record the pressure value of each workpiece that meets the quality standard during the processing, and calculate the pressure average.
- the locking bolt of the dovetail groove can be directly adjusted, and the inclination angle of the dovetail can be used to achieve a uniform pre-tightening force, so that the pressure sensor can also output without the processing pressure.
- a certain pressure value can eliminate background noise and improve measurement accuracy and quality.
- the pre-processing in this step may also be carried out without going directly.
- the purpose of pre-processing is to understand the state of the machine itself and the core plate. In the case of the same wire-cutting machine and the wire-drawing plate, the pressure value during the twisting process is detected, the data is accumulated, and the accurate measurement is performed, or Artificial intelligence measurement.
- Step of setting the pressure range set the upper and lower limits of the upper and lower ranges of the pressure mean as the basis for normal processing.
- the setting of the pressure value range, or the setting of the threshold value is very important, both to achieve the purpose of control quality and to prevent misjudgment. Therefore, when the pressure control system is relatively simple, the threshold range should be large, if it is artificial In the case of intelligent judgment, multiple threshold settings can be used to judge this processing situation and give different processing.
- the pressure value of the silk plate can be treated in a variety of ways. It is simple to stop directly. The slightly more complicated is that the workpiece with abnormal pressure is output separately and alarmed if the workpieces behind are abnormal. It is necessary to stop and maintain an alarm. More complicated, multiple pressure value thresholds can be used to separately treat various pressure conditions, such as a sudden decrease or increase in pressure, indicating that machining abnormalities occur. If the pressure is gradually reduced, the wire is worn. After a certain degree, the silk plate should be replaced.
- This embodiment is a modification of the ninth embodiment and is a refinement of the steps of the ninth process.
- the processing step described in this embodiment when the pressure exceeds the upper limit or the lower limit, the parts with abnormal pressure are separated, and the next workpiece is alarmed and continues to be processed. If the pressure continues to be abnormal, the machine stops, and if the pressure abnormally disappears, the processing continues. Process, but keep the alarm.
- the pressure is gradually reduced to the lower pressure limit, indicating that the wear of the wire is stopped to maintain or replace the wire.
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Abstract
一种带竖直调节架的搓丝机和搓丝方法，包括：安装有滑动搓丝板（1）的床身（2），所述的床身（2）上设有通过螺栓固定的搓板架（3），所述的搓板架（3）上设有与搓丝方向垂直的竖槽，所述的竖槽通过锁紧螺栓（4）与带有与竖槽相配合的竖楔（501）的竖直调节架（5）连接，所述的竖直调节架（5）上设有横槽（502），所述的横槽（502）通过锁紧螺栓（6）与固定搓丝板（7）连接。在固定搓丝板（7）和搓板架（3）之间增加了竖直调节架（5），使固定搓丝板（7）能够上下左右移动调整，并通过锁紧螺栓（4，6）固定，还可以设置调节螺栓进行位移的微调，使整个搓丝板对牙过程变得十分轻松快捷，大大减少了辅助时间，提高了生产效率。使用竖直调节架（5）能够实现完全的自动化对牙调整。同时设置压力传感器能够获得搓丝过程的压力数据，并作为搓制质量控制的重要依据。
Description
本发明涉及一种带竖直调节架的搓丝机和方法，是一种机械加工设备和方法，是一种螺纹加工设备和方法。
现有的搓丝机，通常通过压板将搓丝板固定在床身或滑动托板上。这种结构虽然简单可靠，但对牙过程(调整两块搓丝板相对位置)十分精细、麻烦，需要操作工反复的调整搓丝板的竖向(与搓丝方向垂直)位置和横向(与搓丝方向一致)位置。搓丝板的竖向位置通常需要通过磨制搓丝板的底部(去掉微量的高度)或者在搓丝板底部加垫(微量增加搓丝板的高度)实现，而搓丝板横向位置则需要松开压板螺栓，微量的前后移动搓丝板，达到调整的目的。搓丝板的调整过程消耗了许多辅助时间，即便是一个熟练的操作工，也需要十几分钟的时间才能完成。如何加快调整并实现自动化，是现代搓丝行业面临的问题。
发明内容
为了克服现有技术的问题，本发明提出了一种带有竖直调节架的搓丝机和方法。所述的搓丝机和方法在固定搓丝板和床身之间设置了能够上下调整的竖直调节架，方便了固定搓丝板的调整。
本发明的目的是这样实现的：一种带竖直调节架的搓丝机，包括：安装有滑动搓丝板的床身，所述的床身上设有通过螺栓固定的搓板架，所述的搓板架上设有与搓丝方向垂直的竖槽，所述的竖槽通过锁紧螺栓与带有与竖槽相配合的竖楔的竖直调节架连接，所述的竖直调节架上设有横槽，所述的横槽通过锁紧螺栓与固定搓丝板连接。
进一步的，所述的竖直调节架上设有横向微调螺栓。
进一步的，所述的竖楔上设有竖向微调螺栓。
进一步的，所述的竖楔和竖槽是燕尾楔和燕尾槽。
进一步的，燕尾楔和燕尾槽之间设有至少一个压力传感器。
进一步的，所述的床身上还安装有自动出料分料器。
进一步的，所述的压力传感器与能够记录和显示压力值的压力控制器连接，所述的压力控制器与自动出料分料器和搓丝机的启停控制器连接。
进一步的，所述的压力控制器是PLC、工控计算机、单片机中的一种。
一种使用上述搓丝机的搓丝方法，所述方法的步骤如下：
安装和调整搓丝板的步骤：将固定搓丝板插入竖直调节架的横槽，通过横槽调整固定搓丝板的横向位置，同时通过燕尾楔和燕尾槽调整搓丝板的竖向位置，使固定搓丝板和滑动搓丝板的位置配合，搓制出合格的工件；
预加工的步骤：调整竖向锁紧螺栓，使压力传感器受到预紧力；使用一批材质均匀的工件进行搓丝加工，调整搓丝机和搓丝板达到质量标准，记录每个达到质量标准的工件在加工过程中的压力值，并计算压力均值；
设定压力范围的步骤：设定压力均值上下变化范围的上限和下限，作为正常加工的依据；
加工的步骤：在加工过程中突然出现压力异常，超过压力上限或下限，说明出现加工异常则停机；或者经过一段时间加工运行后，压力逐渐减小至压力下限，说明搓丝板磨损则停机。
进一步的，所述的加工的步骤中，压力超过上限或下限时，将压力异常的零件分出，同时告警并继续加工下一个工件，如果压力继续异常，则停机，如果压力异常消失则继续加工进程，但保留告警。
本发明产生的有益效果是：本发明在固定搓丝板和搓板架之间增加了竖直调节架，使固定搓丝板能够上下左右移动调整，并通过锁紧螺栓固定，还可以设置调节螺栓进行位移的微调，使整个搓丝板对牙过程变得十分轻松快捷，大大减少了辅助时间，提高了生产效率。使用竖直调节架能够实现完全的自动化对牙调整。同时设置压力传感器能够获得搓丝过程的压力数据，并作为搓制质量控制的重要依据。
下面结合附图和实施例对本发明作进一步说明。
图1是本发明的实施例一所述搓丝机的结构示意图；
图2是本发明的实施例一所述搓丝机的结构示意图，是图1中的A向放大图；
图3是本发明的实施例一所述竖直调节架的结构示意图；
是本发明的实施例一所述的
实施例一：
本实施例是一种带有竖直调节架的搓丝机，如图1、2、3所示。本实施例包括：安装有滑动搓丝板1的床身2，所述的床身上设有通过螺栓固定的搓板架3，所述的搓板架上设有与搓丝方向垂直的竖槽，所述的竖槽通过锁紧螺栓4与带有与竖槽相配合的竖楔501的竖直调节架5连接，所述的竖直调节架上设有横槽502，所述的横槽通过锁紧螺栓6与固定搓丝板7连接。
通常情况下，滑动搓丝板通过压板和锁紧螺栓8安装在滑动托板9上，在动力的带动下往复运动，搓动工件10运动的同时对工件外圆面进行加工。本实施例采用了这一传统的安装方式。
本实施例的重点在于固定搓丝板的安装方式。通常情况下，固定搓丝板通过搓板架连接在床身上，本实施例是在搓板架的基础上再增加一个竖直调节架，即：固定搓丝板与竖直调节架连接，竖直调节架与搓板架连接，搓板架再与床身连接。
设置竖直调节架的意义在于，方便固定搓丝板的竖向位置微调，以便更换搓丝板时对牙。传统的固定搓丝板安装在搓板架的横槽中，所以搓板架俗称搓板箱。固定搓丝板通过压板和螺丝固定在搓板箱中，通过松开压板和螺栓，可以方便的横向移动固定搓丝板，即横向调节搓丝板的位置，进行对牙。对牙是一个十分精细的工作，除了横向调节搓丝板点位置之外，有时还有调节搓丝板的上下位置，为此，本实施例设置了竖槽和竖楔，通过竖槽和竖楔的配合，形成竖直上下的调节机构。本实施例采取了横槽的设置，横槽的一端可以设计为封闭的，这样，在封闭端设置横向微调螺栓，细微的调节固定搓丝板的横向位置。同理，竖槽也可以设计为一端封闭，并设置竖向微调螺栓，细微的调节固定搓丝板的横向位置。
竖楔和竖槽可以设计为矩形楔和矩形槽，或者燕尾楔和燕尾槽。
在竖楔和竖槽之间可以设置至少一个压力传感器，以检测搓丝压力，并利用搓丝压力值的变化判断搓丝过程是否正确无误。如果发现压力值异常，可以通过出料分料器将压力值异常的工件排出，如果连续发现压力值异常则停机并告警，以此产生在线监测生产质量的效果。
因此，为配合压力传感器，在床身上还可以设置自动出料分料器，以及压力传感器相配合的压力控制器等设施。由于控制过程十分简单，压力控制器可以是PLC、单片机等简单的控制装置，也可以是复杂的工控计算机等。使用复杂的工控计算机可以进行复杂的过程控制，如对压力值进行精确的检测和计算，设定多个控制阈值对压力值的变化进多层次的控制等。
实施例二：
实施例是实施例一的改进，是实施例一关于竖直调节架的细化。本实施例所述的竖直调节架上设有横向微调螺栓11，如图2所示。
本实施例所述的横向微调螺栓是调节搓丝板横向位置的位移，所谓横向位置的位移是指与滑动搓丝板运动方向一致的位移方向。设置横向微调螺栓可以有两种方式，一种是在搓丝板上设置螺纹孔，使调节螺栓穿过搓丝板，并使调节螺栓顶住横槽的一端的侧壁，利用 螺栓的旋转进给推动搓丝板横向移动。另一个方式是在横槽封闭的一端设置螺纹孔503(见图3)，调节螺栓穿过横槽封闭一端的侧壁，顶住搓丝板，进行微调。
实施例三：
本实施例是上述实施例的细化，是上述实施例关于竖楔的细化。本实施例所述的竖楔上设有竖向微调螺栓12，如图1、2所示。
本实施例是在竖直调节架的竖楔设置带有螺纹的调节孔504，如图3所示，调节螺栓穿过竖楔，调节螺栓顶在竖槽封闭一端的侧壁上，利用螺栓旋转带动竖直调节架竖向(上下)移动。
本实施例所谓的竖向位移是指与滑动搓丝板移动方向垂直的位移方向。
实施例四：
本实施例是上述实施例的细化，是上述实施例关于竖楔和竖槽的细化。本实施例所述的竖楔和竖槽是燕尾楔和燕尾槽，如图2、3所示。
燕尾槽和燕尾楔的配合，两者结合的平面可以有两种选择，一种是两侧肩部的结合，而槽底楔顶是分离的，另一种是槽底和楔顶是结合的，而两侧的肩部的分离的。在燕尾槽作为导轨使，通常采用两侧肩部结合的方案，而本实施例则结合下面的实施例五，在槽底设置压力传感器，利用燕尾槽的楔形，在侧面锁紧螺栓的作用下，能够传递均匀的压力，同时提供均匀的预紧力。这是本实施例的关键所在。
实施例五：
本实施例是上述实施例的细化，是上述实施例关于燕尾楔和燕尾槽的细化。本实施例燕尾楔和燕尾槽之间设有至少一个压力传感器。
压力传感器是一种十分常用的检测元件，有多种类型：应变式、压电式、半导体压敏式等。本实施例可以采用市场出售的各种压力传感器。
设置压力传感器的方式有多种。当搓丝板较小时，可以在搓丝板的中心位置设置一个压力传感器，如果搓丝板较大，则可以在适当的增加传感器的数量，其目的在于尽量均匀的检测搓丝板的整体压力。
为能够测到精确的压力值，可以在燕尾槽的底部设置1-4个压力传感器，以便能够精确的感应搓丝板所受到的压力变化。
如果搓丝板面积较小，可以使用一个传感器，在燕尾槽楔形的作用下，获得均匀的压力。
压力传感器的安装方式也有多种，根据不同的传感器而定，如可以在床身上开槽或 开孔等方式，固定压力传感器，或设置与搓丝板固定连接的竖直调节架，将压力传感器安装在竖直调节架上。
实施例六：
本实施例是上述实施例的细化，是上述实施例关于出料的细化。本实施例所述的床身上还安装有自动出料分料器。
自动出料分料器的作用是将加工过程中搓丝板压力值过大或过小的工件分出。分料器可以采用简单的电磁分料器。
实施例七：
本实施例是上述实施例的细化，是上述实施例关于控制器的细化。本实施例所述的压力传感器与能够记录和显示压力值的压力控制器连接，所述的压力控制器与自动出料分料器和搓丝机的启停控制器连接。
压力控制器可以是简单开关控制器，即压力达到一定数值时即发出信号，利用这个信号关闭搓丝机的电源，即能够达到自动控制质量的效果。有些压力传感器上有阈值设定，可以直接用于控制开关，而无需设置专门的用来控制器。如果复杂一些，则可以使用简单的程序控制器，当出现一个压力异常的工件后，启动自动出料分料器，将这个工件分开输出，当后面的工件联系出现压力异常，则自动停机并告警。这样的控制可以使用成熟的程序控制器，如PLC、单片机等。如果要实现更加复杂的控制，如多个压力传感器的测量值平均计算，或设置测量值数据库，并通过人工智能对测量值进行分析，判断加工情况，这就需要使用工控计算机的相对复杂的系统。
实施例八：
本实施例是上述实施例的细化，是上述实施例关于控制器的细化。本实施例所述的压力控制器是PLC、工控计算机、单片机中的一种。
还可以使用嵌入式系统，如：MUC、片上系统等，通过连接网络实现柔性加工系统。
实施例九：
本实施例是一种使用上述搓丝机的搓丝方法。
搓丝加工是一种高度自动化的超大批大量生产方式。由于是超大批大量的生产，因此希望能尽量减少人为干涉生产过程，或者说尽量实现自动化。自动化生产不但需要自动化的加工，还需要自动化的检测，以保证产品的质量。搓丝加工是一种一致性非常好的加工方式，一般都能够保证加工质量。尽管搓丝生产的一致性好，但也会出现一些特殊的情况，造 成残次品的出现。例如：工件在以不正确的进入加工工位(造成乱牙)、有异形工件混入(直径增大或减小等)、两个工件同时进入加工工位(输料机构误动作)、工件本身材质不均匀等，都会产生加工过程中突然的工件质量变化。这些突发事件中，如果搓丝板没有受到伤害，则加工还能够继续，如果搓丝板遭到破坏，就需要停机维修。还有一种最为常见的情况是搓丝板经过长时间运行后的磨损，需要更换搓丝板。但运行多长时候需要更换，这完全依靠抽样检测和经验。长期以来，搓丝加工没有行之有效的在线检测方式，无法在加工过程中随时对每个工件进行检测，以达到完全质量控制的境界。产生这种状况的原因有二：一是由于搓丝加工单个工件的加工时间太短，一般只有零点几秒，然而，对螺纹的检测，即使是最快的人工目视检测，也至少需要几秒钟的时间。从检测时间上看，对每个工件进行在线检测几乎不可能。二是螺纹检测是一种相对复杂的检测过程，检测螺纹需要使用各种不同的仪器，如何进行快速的在线检测，以及使用什么样的检测方式进行在线检测，在行业中都是难题。现有的方式只能对要求较高的产品进行抽检，即对一个批次的产品进行样本评价，得到的只是这一批产品的质量评价。这种检测方式对搓丝生产这种一致性好的加工方式，还是不错的，但如果批次中有个别次品，通常也无能为力。由此看来在搓丝过程中如何进行在线自动检测，以控制搓丝的质量是一个十分困难的问题，多年来在行业中没有应对的办法。即便是现今在机电一体的大潮中，也没有提出行之有效的办法。
本实施例是一种搓丝在线检测方法。所述方法的基本思路是：利用压力传感器检测搓丝压力，出现压力异常则告警或停机。或者通过检测压力变化判断搓丝板的磨损程度，以便适时更换搓丝板。
本实施例充分利用了搓丝生产过程一致性好的优势，检测搓丝板在加工过程所受到的压力，如果压力均匀，说明生产过程正常，如果发生压力异常变化，则通过停机进行警告，以便操作工进行检验和维修。压力检测是十分常见的检测手段，显示和记录压力数据，以及控制停机都是十分成熟的控制方式。本发明利用这些成熟技术，巧妙的应用在搓丝质量控制上，解决了搓丝生产中在线检测的问题，使意外造成的损坏得以控制，同时对在什么时间、什么情况下更换搓丝板有了明确的指标，即压力指标，使更换搓丝板有了更加科学的依据。更加有意思的是，通过这种压力检测，还可以控制因更换搓丝板而产生的批次工件的质量差异问题，这也是行业中长期以来无法解决的问题。
所述方法的具体步骤如下：
(1)安装和调整搓丝板的步骤：将固定搓丝板插入竖直调节架的横槽，通过横槽调整固定搓丝板的横向位置，同时通过燕尾楔和燕尾槽调整搓丝板的竖向位置，使固定搓丝板和滑动 搓丝板的位置配合，搓制出合格的工件。
(2)预加工的步骤：调整竖向锁紧螺栓，使压力传感器受到预紧力。使用一批材质均匀的工件进行搓丝加工，调整搓丝机和搓丝板达到质量标准，记录每个达到质量标准的工件在加工过程中的压力值，并计算压力均值。
当使用竖楔和竖槽是燕尾楔和燕尾槽，则可以直接调节燕尾槽的锁紧螺栓，利用燕尾的倾斜角度实现均匀的预紧力，使压力传感器在没有加工压力的状态下，也输出一定的压力值，以此可以消除背景噪声，提高测量精度和质量。
本步骤中的预加工，也可以不进行，而直接进入加工过程。预加工的目的在于对机床本身和搓丝板的状态的了解，在同一台搓丝机和搓丝板的情况下，进行搓丝过程中的压力值的检测，积累数据，实现精确测量，或人工智能测量。
(3)设定压力范围的步骤：设定压力均值上下变化范围的上限和下限，作为正常加工的依据。
压力值范围的设定，或者说阈值的设定非常重要，既要到达控制质量的目的，又要防止误判断，因此，当压力控制系统较为简单时，可以阈值范围应当较大，如果是人工智能判断时则可以采用多个阈值设置，对这种加工情况进行判断并给出不同的处理。
(4)加工的步骤：在加工过程中突然出现压力异常，超过压力上限或下限，说明出现加工异常则停机。或者经过一段时间加工运行后，压力逐渐减小至压力下限，说明搓丝板磨损则停机。
在搓丝加工中，搓丝板受到的压力值出现异常可以多种处理，简单的是直接停机，略微复杂一些的是，将压力异常的工件分开输出并报警，如果后面的工件都是压力异常，就要停机并维持告警。更为复杂的，可以使用多个压力值阈值，对各种压力情况进行分别处理，如压力骤然减小或增加，说明出现加工异常，如果压力逐渐减小，则说明搓丝板磨损，当达到一定程度后就要更换搓丝板。
如果使用数据库和人工智能进行判断，则可以进行更加复杂的控制，如压力变化曲线，压力值大小，进行各种型号的工件、材料等进行判断和不同的加工。
实施例十：
本实施例是实施例九的改进，是实施例九关于加工的步骤的细化。本实施例所述的加工的步骤中，压力超过上限或下限时，将压力异常的零件分出，同时告警并继续加工下一个工件，如果压力继续异常，则停机，如果压力异常消失则继续加工进程，但保留告警。
在加工过程中突然出现压力异常，超过压力上限或下限，说明出现加工异常则停 机，或者将加工异常的工件分开输出并报警，但继续进行加工过程，如果后面的加工压力值恢复正常则继续加工，但如果不能恢复正常，则需要停机并告警。
还有一种情况是，经过一段时间加工运行后，压力逐渐减小至压力下限，说明搓丝板磨损则停机对搓丝板进行维护或更换。
最后应说明的是，以上仅用以说明本发明的技术方案而非限制，尽管参照较佳布置方案对本发明进行了详细说明，本领域的普通技术人员应当理解，可以对本发明的技术方案(比如搓丝机的基本形式、搓丝板的基本形式和安装方式、步骤的先后顺序等)进行修改或者等同替换，而不脱离本发明技术方案的精神和范围。
Claims (10)
- 一种带竖直调节架的搓丝机，包括：安装有滑动搓丝板的床身，所述的床身上设有通过螺栓固定的搓板架，其特征在于，所述的搓板架上设有与搓丝方向垂直的竖槽，所述的竖槽通过锁紧螺栓与带有与竖槽相配合的竖楔的竖直调节架连接，所述的竖直调节架上设有横槽，所述的横槽通过锁紧螺栓与固定搓丝板连接。
- 根据权利要求1所述的搓丝机，其特征在于，所述的竖直调节架设有横向微调螺栓。
- 根据权利要求2所述的搓丝机，其特征在于，所述的竖楔上设有竖向微调螺栓。
- 根据权利要求3所述的搓丝机，其特征在于，所述的竖楔和竖槽是燕尾楔和燕尾槽。
- 根据权利要求4所述的搓丝机，其特征在于，燕尾楔和燕尾槽之间设有至少一个压力传感器。
- 根据权利要求5所述的搓丝机，其特征在于，所述的床身上还安装有自动出料分料器。
- 根据权利要求6所述的搓丝机，其特征在于，所述的压力传感器与能够记录和显示压力值的压力控制器连接，所述的压力控制器与自动出料分料器和搓丝机的启停控制器连接。
- 根据权利要求7所述的搓丝机，其特征在于，所述的压力控制器是PLC、工控计算机、单片机中的一种。
- 一种使用权利要求8所述搓丝机的搓丝方法，其特征在于，所述方法的步骤如下：安装和调整搓丝板的步骤：将固定搓丝板插入竖直调节架的横槽，通过横槽调整固定搓丝板的横向位置，同时通过燕尾楔和燕尾槽调整搓丝板的竖向位置，使固定搓丝板和滑动搓丝板的位置配合，搓制出合格的工件；预加工的步骤：调整竖向锁紧螺栓，使压力传感器受到预紧力；使用一批材质均匀的工件进行搓丝加工，调整搓丝机和搓丝板达到质量标准，记录每个达到质量标准的工件在加工过程中的压力值，并计算压力均值；设定压力范围的步骤：设定压力均值上下变化范围的上限和下限，作为正常加工的依据；加工的步骤：在加工过程中突然出现压力异常，超过压力上限或下限，说明出现加工异常则停机；或者经过一段时间加工运行后，压力逐渐减小至压力下限，说明搓丝板磨损则停机。
- 根据权利要求9所述的方法，其特征在于，所述的加工的步骤中，压力超过上限或下限时，将压力异常的零件分出，同时告警并继续加工下一个工件，如果压力继续异常，则停机，如果压力异常消失则继续加工进程，但保留告警。
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