WO2021037107A1 - 基于叠合量检测的阀芯同步磨削去毛刺一体化方法及系统 - Google Patents

基于叠合量检测的阀芯同步磨削去毛刺一体化方法及系统 Download PDF

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Publication number
WO2021037107A1
WO2021037107A1 PCT/CN2020/111590 CN2020111590W WO2021037107A1 WO 2021037107 A1 WO2021037107 A1 WO 2021037107A1 CN 2020111590 W CN2020111590 W CN 2020111590W WO 2021037107 A1 WO2021037107 A1 WO 2021037107A1
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Prior art keywords
grinding
servo valve
workpiece
deburring
valve core
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PCT/CN2020/111590
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English (en)
French (fr)
Inventor
陈明
安庆龙
明伟伟
王建文
党嘉强
刘畅
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上海交通大学
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Application filed by 上海交通大学 filed Critical 上海交通大学
Publication of WO2021037107A1 publication Critical patent/WO2021037107A1/zh
Priority to US17/475,298 priority Critical patent/US11370081B2/en

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
    • B24B9/00—Machines or devices designed for grinding edges or bevels on work or for removing burrs; Accessories therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
    • B24B27/00—Other grinding machines or devices
    • B24B27/033—Other grinding machines or devices for grinding a surface for cleaning purposes, e.g. for descaling or for grinding off flaws in the surface
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
    • B24B49/00—Measuring or gauging equipment for controlling the feed movement of the grinding tool or work; Arrangements of indicating or measuring equipment, e.g. for indicating the start of the grinding operation
    • B24B49/12—Measuring or gauging equipment for controlling the feed movement of the grinding tool or work; Arrangements of indicating or measuring equipment, e.g. for indicating the start of the grinding operation involving optical means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
    • B24B51/00—Arrangements for automatic control of a series of individual steps in grinding a workpiece

Definitions

  • the invention relates to a technology in the field of mechanical processing and manufacturing, in particular to an integrated method for synchronous grinding and deburring of a valve core based on detection of overlap amount and an automatic deburring system applying the method.
  • Electro-hydraulic servo valves have been widely used in hydraulic servo systems.
  • Servo valve cores are mainly ground by precision cylindrical grinders.
  • the last process of valve core processing is to rely on grinding (end surface grinding) to work side, tight Then manual deburring.
  • This traditional process has problems such as low working efficiency, manual deburring process is easy to destroy the integrity of the working side, and the scrap rate of workpieces is high.
  • there are also some other related new technologies for deburring workpieces such as CNC deburring systems, robot-based deburring workstations, etc. Most of them use new automated equipment to replace traditional grinder equipment and replace manual work to complete the entire process of deburring.
  • the efficiency of the deburring process is improved; but for the burr removal process of the servo valve core, it fails to combine the detection and feedback of the performance index of the workpiece product at the same time, so it is not suitable for the industry of high-precision servo valve products batch processing
  • the production line has large application limitations.
  • the present invention proposes an integrated method for synchronous grinding and deburring of valve cores based on detection of overlap and an automated deburring system using the method, which adopts servo valve core workpieces to be synchronously ground to remove burrs.
  • the burr special grinder and the industrial loading and unloading robot combined with the electro-hydraulic servo valve computer pneumatic grinding test bench, realize the automation and integration of the synchronous grinding and deburring processing of the servo valve core and the detection of the overlap amount, and there is no need for manual auxiliary processing and processing. It has the advantages of high efficiency, high manufacturing precision, and high yield; the system unit has a clear functional division of labor, flexible assembly and debugging, and a high degree of flexibility. It is suitable for combination with actual servo valve industrial production lines.
  • the invention relates to a valve core synchronous grinding and deburring integrated processing method based on superimposition amount detection.
  • a servo valve core synchronous grinding and deburring grinder completes automatic valve core clamping and synchronous precision grinding and deburring of working edges. Burr, use industrial loading and unloading robots to grab and transport valve core workpieces. With the assistance of visual CCD industrial camera detection, the automatic assembly of the servo valve sliding pair is completed. The servo valve sliding pair is automatically assembled by the electro-hydraulic servo valve computer pneumatic grinding test bench. The overlap amount of the clamp and the servo valve is automatically detected, and the system industrial control console realizes the real-time control of the complete work flow of the system and the adaptive control of processing parameters.
  • the servo valve core synchronous grinding and deburring grinder integrates: a valve core workpiece automatic clamping mechanism, a workpiece clamping detection system, a valve core grinding processing system and a valve core automatic deburring system.
  • the servo valve core synchronous grinding The deburring grinder realizes the synchronous grinding processing and automatic deburring of the servo valve core on the same equipment, and can cooperate with the external industrial robot to automatically clamp the valve core workpiece, and detect whether the clamping process is completed, and feedback and output the clamping completion signal .
  • the said automatic valve core clamping means the robot grabs the workpiece to be processed and transports it to the jaws of the synchronous grinding and deburring grinder.
  • the automatic clamping mechanism on the grinder opens the jaws and clamps the valve core workpiece, and the mechanism automatically closes and stabilizes.
  • the spool workpiece is clamped, and the workpiece clamping detection system detects that the workpiece is clamped in place and outputs the signal of completion of the clamping to the system industrial control console.
  • the synchronous precision grinding and deburring of the working edge of the valve core workpiece refers to: the servo valve core synchronous grinding and deburring grinder works, the valve core workpiece is driven to rotate, and the valve core grinding processing system performs the axial direction of the valve core workpiece Rely on grinding; at the same time, the valve core automatic deburring system performs radial feed deburring processing on the valve core workpiece.
  • the described automatic assembly of the servo valve sliding pair means the robot grabs the spool workpiece to the servo valve automatic clamping mechanism of the electro-hydraulic servo valve computer pneumatic grinding test bench, and moves the workpiece close to the servo valve automatic clamping mechanism.
  • the visual CCD industrial camera above the mechanism position detects the pose of the robot end workpiece in real time, and transmits the pose data to the system industrial control console.
  • the system software controls the adjustment of the industrial robot according to the pre-calibrated pose data required for assembly The end pose can meet the assembly requirements of the workpiece, and then the end of the robot controls the spool to move axially to complete the complete assembly of the servo valve spool.
  • the electro-hydraulic servo valve computer pneumatic grinding matching test bench integrates: a servo valve stacking amount detection system, a servo valve automatic clamping mechanism, and a special computer for stacking data processing.
  • the electro-hydraulic servo valve computer pneumatic grinding matching test bench It can cooperate with external industrial robots to realize automatic assembly of spool-valve sleeve sliding pair, realize automatic clamping of servo valve, detect the overlap amount of servo valve and preliminarily process the measured data, and then output it.
  • the automatic clamping of the servo valve sliding pair means: in the above-mentioned automatic assembly process of the servo valve sliding pair, when the visual CCD industrial camera detects that the position of the spool workpiece is consistent with the valve sleeve, that is, the assembly is completed, the system industrial control console Control the work flow, control the servo valve automatic clamping mechanism of the electro-hydraulic servo valve computer pneumatic grinding test bench to function, and the servo valve is clamped in place as a whole.
  • the automatic detection of the overlap amount of the servo valve refers to: the servo valve overlap detection system of the servo valve core synchronous grinding and deburring grinder automatically detects the overlap amount of the servo valve sliding pair, and is dedicated to the data processing of the overlap amount.
  • Computer real-time communication the original measurement data is processed by the special computer for data processing of superimposition, and the test result data is output to the system industrial control console.
  • the industrial control console of the system includes: a central control module, and a grinder control module, a robot control module, a test bench control module, and a visual inspection module connected to the central control module, wherein: the grinder control module and the servo valve core synchronize grinding and deburring grinder Connect and monitor the working status of the grinder, and transmit the control signal of the grinder.
  • the robot control module is connected to the loading and unloading industrial robot and monitors the working state of the robot to transmit the robot motion control signal.
  • the test bench control module is connected to the electro-hydraulic servo valve computer pneumatic grinding test bench and Monitor the working status of the test bench, transmit the control signal of the test bench, the visual inspection module is connected with the visual CCD industrial camera and monitor the position and posture signal of the workpiece during the assembly of the servo valve sliding pair. It has a user-oriented workflow operation panel and central control of the control interface. The module processes the status data from other modules to obtain the system real-time workflow control instruction data.
  • the real-time control of the complete work flow of the system and the adaptive control of processing parameters means that the system software judges whether the overlap of the servo valve composed of the current spool and the grinding test bench can meet the preset requirements, if not, according to the current workpiece
  • the measured overlap amount data is processed and calculated to determine the feed amount required for the next grinding process, and then the robot transports the valve core to the grinder to perform the synchronous grinding and automatic deburring process again; if it has reached According to the preset requirements, the automatic clamping mechanism is opened, and the coordinated robot unloads the processed workpiece to complete the processing operation of the workpiece, and the grinding and deburring of the next workpiece to be processed can be carried out.
  • the invention relates to a valve core synchronous grinding and deburring integrated processing system based on superimposition amount detection, which includes: a system industrial control console and a servo valve core synchronous grinding and deburring grinder, an industrial loading and unloading robot, and a servo valve core synchronous grinding and deburring grinder respectively connected to it.
  • Electro-hydraulic servo valve computer pneumatic grinding test bench and visual CCD industrial camera in which: the servo valve core synchronous grinding and deburring grinder outputs the valve core real-time processing status signal and receives the work flow control signal, and the industrial loading and unloading robot outputs the workpiece during transportation The real-time position signal of the robot end and receive the work flow control signal, the electro-hydraulic servo valve computer pneumatic grinding test bench outputs the detection data of the servo valve overlap and receives the work flow control signal, and the visual CCD industrial camera outputs the measured real-time pose data of the workpiece And receive the work process control signal; the system industrial control console receives and processes the work status signals and measurement data from other work units, and then outputs the work process control signals of each work unit according to the established work flow, according to the feedback signal of the sensor system The data is processed to adjust the processing parameters to realize the real-time communication and control of each system unit in the process of synchronous grinding, deburring and overlap detection, as well as the adaptive control of processing parameters.
  • the present invention is based on the integrated application of a series of manufacturing equipment required for the mass production of electro-hydraulic servo valves, and reasonably improves the working modules according to the requirements of the process process, and can realize the synchronous grinding of the electro-hydraulic servo valve spool.
  • the automation and integration of cutting processing, deburring processing and lamination amount detection improves the processing efficiency and yield of valve core workpieces; the manufacturing process of valve core workpieces has a high level of automation without manual auxiliary processing, which reduces the labor cost of product manufacturing and improves
  • the safety and reliability of the manufacturing process are improved;
  • the system unit has a clear division of labor, flexible assembly and debugging, and a high degree of flexibility. It is suitable for industrial large-scale servo valve production lines.
  • Figure 1 is a schematic diagram of an integrated processing system for synchronous grinding and deburring of the valve core of the present invention
  • Fig. 2 is a flowchart of an integrated processing method for synchronous grinding and deburring of the valve core of the present invention.
  • This embodiment is mainly aimed at synchronous grinding and deburring of servo valve core workpieces with high-precision working edge requirements, and at the same time, the overlap amount detection is required. Specifically, the servo valve core working edge grinding and micro-burr removal and automatic detection, The integration of the work flow, such as outputting the servo valve overlap amount data, is realized.
  • this embodiment relates to a valve core synchronous grinding and deburring integrated system based on superimposition amount detection, including: servo valve core synchronous grinding and deburring grinder, industrial loading and unloading robot, electro-hydraulic servo Valve computer pneumatic grinding test bench, visual CCD industrial camera and system industrial control console, including: system industrial control console and servo valve core synchronous grinding and deburring grinder, industrial loading and unloading robot, electro-hydraulic servo valve computer pneumatic grinding test bench , Vision CCD industrial camera and other system units are electrically connected to realize the real-time communication and control of the working units of each system in the process of synchronous grinding, deburring and superposition detection, as well as adaptive control of processing parameters.
  • the servo valve core synchronous grinding and deburring grinder structure is integrated: the valve core grinding processing system, the valve core workpiece automatic clamping mechanism and the workpiece clamping detection system.
  • the valve core automatic deburring system can be installed on this single device. Realize the synchronous grinding processing and automatic deburring of the servo valve core, and can cooperate with the external industrial robot to automatically clamp the valve core workpiece, and detect whether the clamping process is completed, feedback and output the clamping completion signal to the system industrial control console, and receive at the same time Work control signal.
  • the valve core grinding and processing system includes: a grinding head holder and a grinding tail holder for supporting a workpiece, a grinding wheel used for driving the grinding workpiece, and a grinding wheel holder used for grinding feed, including: a grinding head holder and a grinding tail A chuck and a center for clamping and fixing the workpiece are correspondingly arranged on the frame.
  • the automatic clamping mechanism of the valve core workpiece includes: a ball screw slide table, a servo motor, a motor drive and a controller, wherein: the ball screw slide table is connected to the tail grinding frame of the valve core grinding processing system and is driven by the motor And the controller controls the output angular displacement and torque of the servo motor, and then drives the ball screw slide table to move along the axial direction of the workpiece, and controls the overall transmission of the grinding end frame, so that the grinding head frame and the end grinding frame cooperate with each other to clamp the workpiece;
  • the drive and controller are connected with the system industrial control console to realize the motor drag control.
  • the workpiece clamping detection system includes: an embedded pressure sensor and an embedded controller.
  • the embedded pressure sensor is arranged inside the mechanical connection between the ball screw slide table and the grinding tail frame of the grinder, and the workpiece is measured.
  • the pressure value of the tailstock is output and the measured analog quantity is output to the embedded controller; the embedded controller converts the pressure analog quantity into a digital quantity, stores the preliminary data, and outputs it to the system industrial control console.
  • the industrial loading and unloading robot is electrically connected with the system industrial control console to feedback and output robot motion and end position signals to the system industrial control console while receiving work control signals.
  • the structure of the electro-hydraulic servo valve computer pneumatic grinding matching test bench is integrated: a servo valve superimposed amount detection system, a servo valve automatic clamping mechanism, and a special superimposed data processing computer.
  • the electro-hydraulic servo valve computer pneumatic distributing grinding The test bench can cooperate with external industrial robots to realize automatic assembly of spool-valve sleeve sliding pair, realize automatic clamping of servo valve, detect the overlap amount of servo valve and preliminarily process the measured data, and then output it.
  • the visual CCD industrial camera is electrically connected with the system industrial control console to feed back and output the posture data of the workpiece at the end of the robot when the servo valve sliding pair is assembled to the system industrial control console.
  • the industrial control console of the system includes: a grinder control module, a robot control module, a test bench control module, a visual inspection module, and a central control module.
  • the grinder control module is connected to the servo valve core synchronous grinding and deburring grinder and monitors the work of the grinder Status, transmission of grinder work control signals
  • the robot control module is connected to the loading and unloading industrial robot and monitors the working status of the robot
  • the robot motion control signal is transmitted
  • the test bench control module is connected to the electro-hydraulic servo valve computer pneumatic grinding test bench and monitors the working status of the test bench , Transmit the test bench work control signal
  • the visual inspection module is connected with the visual CCD industrial camera and monitor the position and posture signal of the workpiece when the servo valve slide is assembled
  • the central control module processes the status data of other modules to obtain the system real-time workflow control instruction data, and Provide users with corresponding work flow operation panels and control interfaces.
  • this embodiment relates to an integrated processing method for synchronous grinding and deburring of a valve core based on the detection of the overlap amount of the above system, which includes the following steps:
  • Step 1) Automatic clamping of the workpiece by the grinder the robot control module of the industrial control console of the system communicates with the loading and unloading robot in real time.
  • the robot grabs the spool workpiece to be processed, and places the workpiece to the spool for synchronous grinding and automatic clamping of the workpiece on the deburring grinder.
  • System Department. After the workpiece clamping detection system of the spool synchronous grinding and deburring grinder detects that the workpiece is placed in place, the grinder control module of the system's industrial control console communicates with the spool synchronous grinding and deburring grinder in real time, and the spool workpiece automatic clamping mechanism operates Its function, stable clamping of the workpiece;
  • Step 2) Synchronous spool grinding and edge deburring: After the workpiece is clamped and stabilized, the spool grinding and processing system and the spool automatic deburring system of the spool synchronous grinding and deburring grinder start to operate, and the grinder processing equipment automatically operates. Grind the end face of the workpiece for axial matching and grinding, while the deburring system removes edge burrs. At the same time, the grinder control module of the system industrial control console communicates with the valve core synchronous grinding and deburring grinder in real time.
  • the system industrial control console controls the work flow of the valve core synchronous grinding and deburring grinder, and the valve core grinding
  • the processing system stops, the working parts of the automatic deburring system return to their working origin, and the automatic workpiece clamping mechanism opens automatically;
  • Step 3 The workpiece is transferred to the electro-hydraulic servo valve computer pneumatic grinding test bench: the robot control module of the system industrial control console communicates with the loading and unloading industrial robot in real time. The robot grabs the workpiece from the grinder fixture and transfers the workpiece to the electro-hydraulic servo valve At the corresponding position of the servo valve sliding pair automatic assembly system of the computer pneumatic grinding test bench, the servo valve sliding pair is ready to be assembled;
  • Step 4) Servo valve sliding pair automatic assembly and clamping:
  • the visual CCD industrial camera automatically detects the real-time pose data of the robot end workpiece and transmits it to the visual inspection module of the system industrial control console.
  • the visual inspection module and the system software module exchange data and information ,
  • the system software processes the pose compensation amount of the workpiece according to the pose data required for pre-calibrated valve core assembly.
  • the robot control module communicates with the loading and unloading industrial robot in real time to control the industrial robot to adjust the end pose to meet the assembly requirements of the workpiece sliding pair; then the robot end controls the spool axial movement to complete the valve sleeve-spool sliding pair assembly, and then the servo valve
  • the automatic clamping mechanism performs its function in preparation for the detection of the overlap amount
  • Step 5) Servo valve overlap amount automatic detection, processing flow and parameter adaptive control:
  • the servo valve computer pneumatic grinding test bench performs the servo valve overlap amount detection, and then outputs the detection data to the test bench control module of the system industrial control console.
  • the test bench control module and the system software module exchange data and information.
  • the system software judges whether the current spool valve is equipped with a grinding overlap amount that meets the preset requirements. If it does not, it determines the progress of the next round of grinding processing according to the current overlap amount data. Give the amount.
  • the robot transports the valve core to the grinder, and the above process flow is performed again; if the requirements are met, the workpiece automatic clamping mechanism opens, and the coordinated robot unloads the processed workpiece to complete the processing of the workpiece, and the next workpiece to be processed can be deburred.
  • the work flow loops through the above steps again.
  • This embodiment aims at the automated production process of the electro-hydraulic servo valve spool, and is based on a special grinder for synchronous grinding and deburring of the spool, combined with a servo valve computer pneumatic grinding test bench, and the workpiece is transported by an industrial loading and unloading robot to realize the servo spool
  • the automation and integration of the synchronous grinding and deburring process and the detection process of the servo valve product overlap effectively overcome the shortcomings of the existing process and technical methods, replace the traditional manual assistance, reduce labor costs, and effectively upgrade the valve
  • the processing efficiency and yield of the core at the same time, the system equipment is relatively independent, with clear functions, high flexibility and intelligence, and is suitable for modern high-precision servo valve batch processing production lines.
  • the test material is 440C stainless steel bar
  • the diameter of the workpiece is 10 mm
  • the radial runout of the workpiece is 0.18 ⁇ m
  • the feed speed is 8 ⁇ m/s
  • the rotation speed of the workpiece is 180 rpm
  • the number of processed pieces is 100 pieces.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Grinding And Polishing Of Tertiary Curved Surfaces And Surfaces With Complex Shapes (AREA)
  • Constituent Portions Of Griding Lathes, Driving, Sensing And Control (AREA)

Abstract

一种基于叠合量检测的阀芯同步磨削去毛刺一体化方法及及应用该方法的自动化去毛刺系统，由伺服阀芯同步磨削去毛刺磨床完成阀芯自动装夹和工作棱边的同步精密磨削与去毛刺，通过工业上下料机器人来抓取并运送阀芯工件，在视觉CCD工业相机检测辅助下完成伺服阀滑副自动装配，由电液伺服阀计算机气动配磨测试台进行伺服阀滑副自动装夹和伺服阀叠合量自动检测，系统工控操作台实现系统完整工作流程实时控制及加工参量自适应控制。本发明实现伺服阀芯同步磨削去毛刺加工和叠合量检测的自动化和一体化，具有无需人工辅助加工、加工效率高、制造精度高、成品率高等优点；系统单元功能分工明确，组装和调试灵活，柔性化程度高，适合与实际伺服阀工业生产线相结合。

Description

基于叠合量检测的阀芯同步磨削去毛刺一体化方法及系统 技术领域
本发明涉及的是一种机械加工制造领域的技术，具体是一种基于叠合量检测的阀芯同步磨削去毛刺一体化方法及应用该方法的自动化去毛刺系统。
背景技术
电液伺服阀在液压伺服系统中得到了广泛的应用，其中的伺服阀阀芯主要采用精密外圆磨床进行磨削加工，阀芯加工最后一道工序为靠磨(端面磨削)工作边，紧接着手工去毛刺，这种传统工艺存在工作边加工效率低下、手工去毛刺过程易破坏工作边完整性、工件报废率高等问题。同时，目前也有一些其他相关的工件去毛刺新型技术，比如数控去毛刺系统、基于机器人的去毛刺工作站等，大都是采用新型自动化设备替代传统磨床设备并取代人工完成工件的毛刺去除全过程，在一定程度上提升了去毛刺工艺的效率；但针对伺服阀芯的毛刺去除工艺，其未能同时结合对工件产品性能指标的检测与反馈，因而不适用于高精度伺服阀产品批量化加工的工业生产线，存在较大的应用局限性。
发明内容
本发明针对现有技术存在的上述不足，提出一种基于叠合量检测的阀芯同步磨削去毛刺一体化方法及及应用该方法的自动化去毛刺系统，采用伺服阀芯工件同步磨削去毛刺专用磨床和工业上下料机器人，结合电液伺服阀计算机气动配磨测试台，实现了伺服阀芯同步磨削去毛刺加工和叠合量检测的 自动化和一体化，具有无需人工辅助加工、加工效率高、制造精度高、成品率高等优点；系统单元功能分工明确，组装和调试灵活，柔性化程度高，适合与实际伺服阀工业生产线相结合。
本发明是通过以下技术方案实现的：
本发明涉及一种基于叠合量检测的阀芯同步磨削去毛刺一体化加工方法，由伺服阀芯同步磨削去毛刺磨床完成阀芯自动装夹和工作棱边的同步精密磨削与去毛刺，通过工业上下料机器人来抓取并运送阀芯工件，在视觉CCD工业相机检测辅助下完成伺服阀滑副自动装配，由电液伺服阀计算机气动配磨测试台进行伺服阀滑副自动装夹和伺服阀叠合量自动检测，系统工控操作台实现系统完整工作流程实时控制及加工参量自适应控制。
所述的伺服阀芯同步磨削去毛刺磨床中集成有：阀芯工件自动装夹机构、工件装夹检测系统、阀芯磨削加工系统和阀芯自动去毛刺系统，该伺服阀芯同步磨削去毛刺磨床在同一设备上实现伺服阀芯的同步磨削加工和自动化去毛刺，能够配合外部工业机器人进行阀芯工件的自动装夹，并检测装夹过程是否完成，反馈输出装夹完成信号。
所述的阀芯自动装夹是指：机器人抓取待加工工件运送至同步磨削去毛刺磨床卡爪处，磨床上的自动装夹机构打开卡爪并卡紧阀芯工件，机构自动闭合稳定装夹阀芯工件，工件装夹检测系统检测到工件装夹到位后向系统工控操作台输出工件装夹完成信号。
所述的阀芯工件工作棱边的同步精密磨削与去毛刺是指：伺服阀芯同步磨削去毛刺磨床工作，驱动阀芯工件旋转，阀芯磨削加工系统对阀芯工件进行轴向靠磨；同时，阀芯自动去毛刺系统对阀芯工件进行径向进给的去毛刺加 工。
所述的伺服阀滑副自动装配是指：机器人抓取阀芯工件至电液伺服阀计算机气动配磨测试台的伺服阀自动装夹机构处，移动工件靠近伺服阀自动装夹机构所夹持的阀套，同时机构位置上方的视觉CCD工业相机实时检测机器人末端工件位姿，将位姿数据传输至系统工控操作台，系统软件根据预标定的装配所需的位姿数据，控制工业机器人调节末端位姿以达到工件装配要求，进而机器人末端控制阀芯进行轴向运动从而完成伺服阀滑副完全装配。
所述的电液伺服阀计算机气动配磨测试台中集成有：伺服阀叠合量检测系统、伺服阀自动装夹机构、叠合量数据处理专用计算机，该电液伺服阀计算机气动配磨测试台能够配合外部工业机器人实现阀芯-阀套滑副的自动装配，实现伺服阀的自动装夹，检测伺服阀叠合量并初步处理所测数据，而后将其输出。
所述的伺服阀滑副自动装夹是指：在上述的伺服阀滑副自动装配过程中，当视觉CCD工业相机检测到阀芯工件位姿与阀套一致即装配完成后，系统工控操作台进行工作流程控制，控制电液伺服阀计算机气动配磨测试台的伺服阀自动装夹机构行使功能，进行伺服阀整体装夹到位。
所述的伺服阀叠合量自动检测是指：伺服阀芯同步磨削去毛刺磨床的伺服阀叠合量检测系统对伺服阀滑副进行叠合量自动检测，同时与叠合量数据处理专用计算机实时通信，由叠合量数据处理专用计算机处理原始测量数据，输出测试结果数据至系统工控操作台。
所述的系统工控操作台包括：中央控制模块以及分别与之相连的磨床控制模块、机器人控制模块、测试台控制模块和视觉检测模块，其中：磨床控制 模块与伺服阀芯同步磨削去毛刺磨床相连并监测磨床工作状态、传输磨床工作控制信号，机器人控制模块与上下料工业机器人相连并监测机器人工作状态传输机器人运动控制信号，测试台控制模块与电液伺服阀计算机气动配磨测试台相连并监测测试台工作状态、传输测试台工作控制信号，视觉检测模块与视觉CCD工业相机相联并监测伺服阀滑副装配时工件位姿信号，具有面向用户的工作流程操作面板和控制接口的中央控制模块处理来自其他模块的状态数据得到系统实时工作流程控制指令数据。
所述的系统完整工作流程实时控制及加工参量自适应控制是指：系统软件判断当前阀芯与配磨测试台所组成的伺服阀叠合量是否能达到预设要求，若未达到，根据工件当前所测得的叠合量数据进行处理运算，确定出下一次磨削加工所需的进给量，而后机器人运送阀芯至磨床，再次进行同步磨削与自动去毛刺加工工序流程；若已达到预设要求，自动装夹机构打开，协同机器人卸下已加工工件，完成本工件加工作业，可进行下一件待加工工件的磨削与去毛刺加工。
本发明涉及一种基于叠合量检测的阀芯同步磨削去毛刺一体化加工系统，包括：系统工控操作台和分别与之相连的伺服阀芯同步磨削去毛刺磨床、工业上下料机器人、电液伺服阀计算机气动配磨测试台和视觉CCD工业相机，其中：伺服阀芯同步磨削去毛刺磨床输出阀芯实时加工状态信号并接收工作流程控制信号，工业上下料机器人输出工件运送过程中机器人末端实时位置信号并接收工作流程控制信号，电液伺服阀计算机气动配磨测试台输出伺服阀叠合量检测数据并接收工作流程控制信号，视觉CCD工业相机输出所测得工件实时位姿数据并接收工作流程控制信号；由系统工控操作台接收来自其 他各工作单元的工作状态信号与测量数据并处理，再按照既定工作流程输出各工作单元的工作流程控制信号，根据传感系统的反馈信号数据进行处理从而调整加工参量，实现同步磨削去毛刺和叠合量检测工作过程中对各系统单元的实时通信与控制，以及加工参量自适应控制。
技术效果
与现有技术相比，本发明基于对电液伺服阀批量生产所需要的一系列制造设备的集成化应用，根据工艺过程需求对工作模块进行合理改进，能够实现电液伺服阀阀芯同步磨削加工、去毛刺加工和叠合量检测的自动化和一体化，提高阀芯工件加工效率和成品率；阀芯工件制造过程自动化水平高，无需人工辅助加工，降低了产品制造的人力成本，提高了制造过程的安全性和可靠性；系统单元分工明确，组装调试灵活，柔性化程度高，适用于工业大批量伺服阀生产线。
附图说明
图1为本发明阀芯同步磨削去毛刺一体化加工系统示意图；
图2为本发明阀芯同步磨削去毛刺一体化加工方法流程图。
具体实施方式
本实施例主要针对有高精度工作棱边要求的伺服阀芯工件进行同步磨削去毛刺，同时需进行叠合量检测，具体为伺服阀阀芯工作边磨削和微小毛刺去除并自动检测、输出伺服阀叠合量数据等工作流程的一体化实现。
如图1所示，为本实施例涉及一种基于叠合量检测的阀芯同步磨削去毛刺一体化系统，包括：伺服阀芯同步磨削去毛刺磨床、工业上下料机器人、电液伺服阀计算机气动配磨测试台、视觉CCD工业相机和系统工控操作台，其中：系统工控操作台与伺服阀芯同步磨削去毛刺磨床、工业上下料机器人、电液伺服阀计算机气动配磨测试台、视觉CCD工业相机等系统单元之间有电气连接，实现同步磨削去毛刺和叠合量检测过程中对各系统工作单元的实时通信和控制，及加工参量自适应控制。
所述的伺服阀芯同步磨削去毛刺磨床结构中集成：阀芯磨削加工系统、阀芯工件自动装夹机构和工件装夹检测系统，该阀芯自动去毛刺系统能够在此单一设备上实现伺服阀芯的同步磨削加工和自动化去毛刺，能够配合外部工业机器人进行阀芯工件的自动装夹，并检测装夹过程是否完成，反馈输出装夹完成信号至系统工控操作台，同时接收工作控制信号。
所述的阀芯磨削加工系统包括：用于支撑工件磨头架和磨尾架、用于驱动磨削工件的砂轮及用于磨削进给的砂轮架，其中：磨头架和磨尾架上对应设有用于夹紧固定工件卡盘和顶尖。
所述的阀芯工件自动装夹机构包括：滚珠丝杠滑台、伺服电机、电机驱动及控制器，其中：滚珠丝杠滑台与阀芯磨削加工系统的磨尾架相连，由电机驱动及控制器控制伺服电机输出角位移和转矩，进而驱动滚珠丝杠滑台沿工件轴向运动，控制磨尾架整体的传动，实现磨头架与磨尾架相互配合，夹紧工件；电机驱动及控制器与系统工控操作台相连以实现电机拖动控制。
所述的工件装夹检测系统包括：嵌入式压力传感器和嵌入式控制器，其中：嵌入式压力传感器设置于滚珠丝杠滑台与磨床的磨尾架之间的机械连接处内部，测量进行工件夹紧工作时磨尾架所受压力值并输出所测模拟量至嵌入式控制器；嵌入式控制器将压力模拟量转换为数字量存储经初步数据处理并输出至系统工控操作台。
所述的工业上下料机器人与系统工控操作台电气连接以反馈输出机器人运动及末端位置信号至系统工控操作台的同时接收工作控制信号。
所述的电液伺服阀计算机气动配磨测试台的结构中集成：伺服阀叠合量检测系统、伺服阀自动装夹机构和叠合量数据处理专用计算机，该电液伺服阀计算机气动配磨测试台能够配合外部工业机器人实现阀芯-阀套滑副的自动装配，实现伺服阀的自动装夹，检测伺服阀叠合量并初步处理所测数据，而后将其输出。
所述的视觉CCD工业相机与系统工控操作台电气连接以反馈输出伺服阀滑副装配时机器人末端的工件位姿数据至系统工控操作台。
所述的系统工控操作台包括：磨床控制模块、机器人控制模块、测试台控制模块、视觉检测模块以及中央控制模块，其中：磨床控制模块与伺服阀芯同步磨削去毛刺磨床相连并监测磨床工作状态、传输磨床工作控制信号，机器人控制模块与上下料工业机器人相连并监测机器人工作状态传输机器人运动控制信号，测试台控制模块与电液伺服阀计算机气动配磨测试台相连并监测测试台工作状态、传输测试台工作控制信号，视觉检测模块与视觉CCD工业相机相联并监测伺服阀滑副装配时工件位姿信号，中央控制模块处理其 他模块的状态数据得到系统实时工作流程控制指令数据，并提供给用户相应的工作流程操作面板和控制接口。
如图2所示，本实施例涉及上述系统的一种基于叠合量检测的阀芯同步磨削去毛刺一体化加工方法，包括以下步骤：
步骤1)磨床自动装夹工件：系统工控操作台的机器人控制模块与上下料机器人进行实时通信，机器人抓取待加工阀芯工件，放置工件至阀芯同步磨削去毛刺磨床的工件自动装夹系统处。阀芯同步磨削去毛刺磨床的工件装夹检测系统检测到工件放置到位后，系统工控操作台的磨床控制模块与阀芯同步磨削去毛刺磨床进行实时通信，阀芯工件自动装夹机构行使其功能，稳定装夹工件；
步骤2)阀芯同步磨削和棱边去除毛刺：工件装夹稳定后，阀芯同步磨削去毛刺磨床的阀芯磨削加工系统和阀芯自动去毛刺系统开始运行，磨床加工设备自动靠磨工件端面，进行轴向配磨，同时去毛刺系统进行棱边毛刺去除。同时，系统工控操作台的磨床控制模块与阀芯同步磨削去毛刺磨床进行实时通信，当加工结束时，系统工控操作台对阀芯同步磨削去毛刺磨床进行工作流程控制，阀芯磨削加工系统停止运转，自动去毛刺系统的工作部件退回至其工作原点，工件自动装夹机构自动打开；
步骤3)工件转移至电液伺服阀计算机气动配磨测试台：系统工控操作台的机器人控制模块与上下料工业机器人进行实时通信，机器人从磨床夹具上抓取工件，转移工件至电液伺服阀计算机气动配磨测试台的伺服阀滑副自动装配系统相应位置处，准备进行伺服阀滑副的装配；
步骤4)伺服阀滑副自动装配与装夹：视觉CCD工业相机自动检测机器人末端工件实时位姿数据，并传输至系统工控操作台的视觉检测模块，视觉检测模块与系统软件模块进行数据信息交换，系统软件根据预先标定的阀芯装配所需的位姿数据，处理得到工件位姿补偿量。同时机器人控制模块与上下料工业机器人进行实时通信，控制工业机器人调节末端位姿以达到工件滑副装配要求；进而机器人末端控制阀芯轴向运动完成阀套-阀芯滑副装配，而后伺服阀自动装夹机构行使其功能，以准备进行叠合量检测；
步骤5)伺服阀叠合量自动检测、加工流程与参数自适应控制：伺服阀计算机气动配磨测试台进行伺服阀叠合量检测，完成后输出检测数据至系统工控操作台的测试台控制模块，测试台控制模块与系统软件模块进行数据信息交换，系统软件判断当前滑阀配磨叠合量是否达到预设要求，若未达到，根据当前叠合量数据确定下一轮磨削加工的进给量。机器人运送阀芯至磨床，再次进行以上工序流程；若达到要求，工件自动装夹机构打开，协同机器人卸下已加工工件，完成本工件加工作业，可进行下一待加工工件的去毛刺加工，工作流程再次循环以上步骤。
本实施例针对电液伺服阀阀芯的自动化生产工艺过程，基于阀芯同步磨削去毛刺专用磨床，结合伺服阀计算机气动配磨测试台，通过工业上下料机器人运送工件，实现了伺服阀芯同步磨削去毛刺工艺过程和伺服阀产品叠合量检测过程的自动化和一体化；有效克服了现有工艺、技术方法的不足，取代了传统的人工辅助，降低了人力成本，有效提升了阀芯的加工效率和成品率；同时，系统设备之间相对独立，功能明确，具有很高的柔性化和智能化，适用于现代高精度伺服阀批量化加工生产线。
本实施例采用试验材料为440C不锈钢棒料，工件直径10mm，工件径向跳动0.18μm；磨床加工时，进给速度8μm/s，工件转速180rpm；加工件数为100件。对本次试验的100个试样全部进行检测后，结果表明，全部符合工作边保持直角锐边无毛刺的加工要求，去毛刺后工作边残余毛刺高度约0.5μm左右，废品率为0。与现有技术相比，本方法的性能指标提升在于：相对于传统人力手工加工，工件加工效率提升了83％，成品率提升至99％以上。
上述具体实施可由本领域技术人员在不背离本发明原理和宗旨的前提下以不同的方式对其进行局部调整，本发明的保护范围以权利要求书为准且不由上述具体实施所限，在其范围内的各个实现方案均受本发明之约束。

Claims (10)

  1. 一种基于叠合量检测的阀芯同步磨削去毛刺一体化加工方法，其特征在于，由伺服阀芯同步磨削去毛刺磨床完成阀芯自动装夹和工作棱边的同步精密磨削与去毛刺，通过工业上下料机器人来抓取并运送阀芯工件，在视觉CCD工业相机检测辅助下完成伺服阀滑副自动装配，由电液伺服阀计算机气动配磨测试台进行伺服阀滑副自动装夹和伺服阀叠合量自动检测，系统工控操作台实现系统完整工作流程实时控制及加工参量自适应控制。
  2. 根据权利要求1所述的基于叠合量检测的阀芯同步磨削去毛刺一体化加工方法，其特征是，所述的伺服阀芯同步磨削去毛刺磨床中集成有：阀芯工件自动装夹机构、工件装夹检测系统、阀芯磨削加工系统和阀芯自动去毛刺系统，该伺服阀芯同步磨削去毛刺磨床在同一设备上实现伺服阀芯的同步磨削加工和自动化去毛刺，能够配合外部工业机器人进行阀芯工件的自动装夹，并检测装夹过程是否完成，反馈输出装夹完成信号；
    所述的阀芯自动装夹是指：机器人抓取待加工工件运送至同步磨削去毛刺磨床卡爪处，磨床上的自动装夹机构打开卡爪并卡紧阀芯工件，机构自动闭合稳定装夹阀芯工件，工件装夹检测系统检测到工件装夹到位后向系统工控操作台输出工件装夹完成信号；
    所述的阀芯工件工作棱边的同步精密磨削与去毛刺是指：伺服阀芯同步磨削去毛刺磨床工作，驱动阀芯工件旋转，阀芯磨削加工系统对阀芯工件进行轴向靠磨；同时，阀芯自动去毛刺系统对阀芯工件进行径向进给的去毛刺加工。
  3. 根据权利要求1所述的基于叠合量检测的阀芯同步磨削去毛刺一体化加工方法，其特征是，所述的伺服阀滑副自动装配是指：机器人抓取阀芯工 件至电液伺服阀计算机气动配磨测试台的伺服阀自动装夹机构处，移动工件靠近伺服阀自动装夹机构所夹持的阀套，同时机构位置上方的视觉CCD工业相机实时检测机器人末端工件位姿，将位姿数据传输至系统工控操作台，系统软件根据预标定的装配所需的位姿数据，控制工业机器人调节末端位姿以达到工件装配要求，进而机器人末端控制阀芯进行轴向运动从而完成伺服阀滑副完全装配。
  4. 根据权利要求1所述的基于叠合量检测的阀芯同步磨削去毛刺一体化加工方法，其特征是，所述的电液伺服阀计算机气动配磨测试台中集成有：伺服阀叠合量检测系统、伺服阀自动装夹机构、叠合量数据处理专用计算机，该电液伺服阀计算机气动配磨测试台能够配合外部工业机器人实现阀芯-阀套滑副的自动装配，实现伺服阀的自动装夹，检测伺服阀叠合量并初步处理所测数据，而后将其输出；
    所述的伺服阀滑副自动装夹是指：在上述的伺服阀滑副自动装配过程中，当视觉CCD工业相机检测到阀芯工件位姿与阀套一致即装配完成后，系统工控操作台进行工作流程控制，控制电液伺服阀计算机气动配磨测试台的伺服阀自动装夹机构行使功能，进行伺服阀整体装夹到位；
    所述的伺服阀叠合量自动检测是指：伺服阀芯同步磨削去毛刺磨床的伺服阀叠合量检测系统对伺服阀滑副进行叠合量自动检测，同时与叠合量数据处理专用计算机实时通信，由叠合量数据处理专用计算机处理原始测量数据，输出测试结果数据至系统工控操作台。
  5. 根据权利要求1所述的基于叠合量检测的阀芯同步磨削去毛刺一体化加工方法，其特征是，所述的系统工控操作台包括：中央控制模块以及分别 与之相连的磨床控制模块、机器人控制模块、测试台控制模块和视觉检测模块，其中：磨床控制模块与伺服阀芯同步磨削去毛刺磨床相连并监测磨床工作状态、传输磨床工作控制信号，机器人控制模块与上下料工业机器人相连并监测机器人工作状态传输机器人运动控制信号，测试台控制模块与电液伺服阀计算机气动配磨测试台相连并监测测试台工作状态、传输测试台工作控制信号，视觉检测模块与视觉CCD工业相机相联并监测伺服阀滑副装配时工件位姿信号，具有面向用户的工作流程操作面板和控制接口的中央控制模块处理来自其他模块的状态数据得到系统实时工作流程控制指令数据；
    所述的系统完整工作流程实时控制及加工参量自适应控制是指：系统软件判断当前阀芯与配磨测试台所组成的伺服阀叠合量是否能达到预设要求，若未达到，根据工件当前所测得的叠合量数据进行处理运算，确定出下一次磨削加工所需的进给量，而后机器人运送阀芯至磨床，再次进行同步磨削与自动去毛刺加工工序流程；若已达到预设要求，自动装夹机构打开，协同机器人卸下已加工工件，完成本工件加工作业，可进行下一件待加工工件的磨削与去毛刺加工。
  6. 一种实现上述任一权利要求所述方法的阀芯同步磨削去毛刺一体化加工系统，其特征在于，包括：系统工控操作台和分别与之相连的伺服阀芯同步磨削去毛刺磨床、工业上下料机器人、电液伺服阀计算机气动配磨测试台和视觉CCD工业相机，其中：伺服阀芯同步磨削去毛刺磨床输出阀芯实时加工状态信号并接收工作流程控制信号，工业上下料机器人输出工件运送过程中机器人末端实时位置信号并接收工作流程控制信号，电液伺服阀计算机气动配磨测试台输出伺服阀叠合量检测数据并接收工作流程控制信号，视觉 CCD工业相机输出所测得工件实时位姿数据并接收工作流程控制信号；由系统工控操作台接收来自其他各工作单元的工作状态信号与测量数据并处理，再按照既定工作流程输出各工作单元的工作流程控制信号，根据传感系统的反馈信号数据进行处理从而调整加工参量，实现同步磨削去毛刺和叠合量检测工作过程中对各系统单元的实时通信与控制，以及加工参量自适应控制。
  7. 根据权利要求6所述的系统，其特征是，所述的工业上下料机器人与系统工控操作台电气连接以反馈输出机器人运动及末端位置信号至系统工控操作台的同时接收工作控制信号；
    所述的视觉CCD工业相机与系统工控操作台电气连接以反馈输出伺服阀滑副装配时机器人末端的工件位姿数据至系统工控操作台。
  8. 根据权利要求6所述的系统，其特征是，所述的阀芯磨削加工系统包括：用于支撑工件磨头架和磨尾架、用于驱动磨削工件的砂轮及用于磨削进给的砂轮架，其中：磨头架和磨尾架上对应设有用于夹紧固定工件卡盘和顶尖。
  9. 根据权利要求6所述的系统，其特征是，所述的阀芯工件自动装夹机构包括：滚珠丝杠滑台、伺服电机、电机驱动及控制器，其中：滚珠丝杠滑台与阀芯磨削加工系统的磨尾架相连，由电机驱动及控制器控制伺服电机输出角位移和转矩，进而驱动滚珠丝杠滑台沿工件轴向运动，控制磨尾架整体的传动，实现磨头架与磨尾架相互配合，夹紧工件；电机驱动及控制器与系统工控操作台相连以实现电机拖动控制。
  10. 根据权利要求6所述的系统，其特征是，所述的工件装夹检测系统包括：嵌入式压力传感器和嵌入式控制器，其中：嵌入式压力传感器设置于滚 珠丝杠滑台与磨床的磨尾架之间的机械连接处内部，测量进行工件夹紧工作时磨尾架所受压力值并输出所测模拟量至嵌入式控制器；嵌入式控制器将压力模拟量转换为数字量存储经初步数据处理并输出至系统工控操作台。
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