WO2022007363A2 - 一种基于分段控制原理的高柔性桌式包边机及包边方法 - Google Patents

一种基于分段控制原理的高柔性桌式包边机及包边方法 Download PDF

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Publication number
WO2022007363A2
WO2022007363A2 PCT/CN2020/141452 CN2020141452W WO2022007363A2 WO 2022007363 A2 WO2022007363 A2 WO 2022007363A2 CN 2020141452 W CN2020141452 W CN 2020141452W WO 2022007363 A2 WO2022007363 A2 WO 2022007363A2
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WO
WIPO (PCT)
Prior art keywords
hemming
tire mold
pressing
knife
door cover
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PCT/CN2020/141452
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English (en)
French (fr)
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WO2022007363A3 (zh
Inventor
刘蕾
方晨程
李骥国
何伟
Original Assignee
安徽巨一科技股份有限公司
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Application filed by 安徽巨一科技股份有限公司 filed Critical 安徽巨一科技股份有限公司
Priority to EP20944762.2A priority Critical patent/EP4112202A4/en
Publication of WO2022007363A2 publication Critical patent/WO2022007363A2/zh
Publication of WO2022007363A3 publication Critical patent/WO2022007363A3/zh

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D39/00—Application of procedures in order to connect objects or parts, e.g. coating with sheet metal otherwise than by plating; Tube expanders
    • B21D39/02—Application of procedures in order to connect objects or parts, e.g. coating with sheet metal otherwise than by plating; Tube expanders of sheet metal by folding, e.g. connecting edges of a sheet to form a cylinder
    • B21D39/021—Application of procedures in order to connect objects or parts, e.g. coating with sheet metal otherwise than by plating; Tube expanders of sheet metal by folding, e.g. connecting edges of a sheet to form a cylinder for panels, e.g. vehicle doors
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
    • B21C51/00—Measuring, gauging, indicating, counting, or marking devices specially adapted for use in the production or manipulation of material in accordance with subclasses B21B - B21F
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D19/00—Flanging or other edge treatment, e.g. of tubes
    • B21D19/08—Flanging or other edge treatment, e.g. of tubes by single or successive action of pressing tools, e.g. vice jaws
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D53/00—Making other particular articles
    • B21D53/88—Making other particular articles other parts for vehicles, e.g. cowlings, mudguards
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D37/00—Tools as parts of machines covered by this subclass
    • B21D37/18—Lubricating, e.g. lubricating tool and workpiece simultaneously

Definitions

  • the invention relates to the technical field of sheet metal processing equipment, in particular to a highly flexible table-top hemming machine and an hemming method based on a segmented control principle.
  • the four doors and two covers of an automobile are an important part of the automobile body assembly. Due to the characteristics of opening and closing, the edges of the four doors and two covers need to be beautiful and smooth. Therefore, the hemming process is compared with welding, riveting and other connection processes. The two covers are irreplaceable.
  • the robot hemming system is mainly composed of hemming fixtures, hemming tools, robots and their control systems. Rolling for many times to achieve the purpose of wrapping the inner plate with the outer plate.
  • the advantages are high flexibility and flexible debugging.
  • the disadvantage is that the rolling speed is slow, and the rhythm is generally not more than 50JPH.
  • the second is that the long-term quality stability is not high. Human maintenance and correction are more.
  • the hemming of the press is mainly composed of the pressure main body and the switchable hemming die.
  • the advantages are fast hemming speed and stable hemming quality, but the disadvantages are large footprint, poor flexibility, and high cost.
  • the disadvantages are large footprint, poor flexibility, and high cost.
  • it is necessary to increase the mold switching track, which increases the time and investment for model switching.
  • the cost is extremely high.
  • the old-fashioned hydraulic press has defects such as loud noise and oil pollution, which cannot comply with the current trend of energy saving and emission reduction.
  • a hemming equipment and method disclosed in patent US20080302161A1 its lifting mechanism mainly adopts a cylinder, a connecting rod, and a cam mechanism to realize the reciprocating lifting function, and cooperates with the pressing mechanism and the plate fixing mechanism to realize the hemming.
  • the lifting structure is relatively It is complex, can withstand relatively small loads, is difficult to control the lifting stroke, and has poor stability.
  • its knife-pressing mechanism is simple in structure, and it is difficult to match different plates of multiple models, and the compatibility is relatively poor.
  • Patent CN203265351U discloses a car door hemming machine, which converts the motor output torque into the forward thrust of the nut seat through the ball screw.
  • the third connecting rod rotates around the fulcrum
  • the first connecting rod and the fifth connecting rod are respectively pushed to rotate around their fulcrum on the main frame, and the force increasing process is completed through the force increasing hinge composed of the second connecting rod and the third connecting rod, that is, the ball screw and the
  • the multi-link mechanism is used to realize the thrust of the hemming, which acts on the pressing mechanism, but the load range that the above structure can bear is small, the stability is poor, and the pressing mechanism is small, which is mainly suitable for the hemming of some narrow spaces.
  • the hemming consistency for the entire door cover is relatively poor.
  • the purpose of the present invention is to provide a highly flexible table-type hemming machine based on the principle of segmented control, so as to realize fast and stable hemming of automobile door covers.
  • the present invention proposes a highly flexible table-top hemming machine based on a segmented control principle, including a base, a tire mold mounting seat, a jacking mechanism, a tire mold set on the tire mold mounting seat, and a tire mold located around the tire mold.
  • Several pressing mechanisms a pressing mechanism on the upper side of the tire mold, and a turning mechanism for driving the rotation of the pressing mechanism; wherein, the jacking mechanism is used to drive the tire mold and the door cover to move up and down, and the pressing mechanism drives the pressing knife to move horizontally The door cover is wrapped; and several sets of pressing mechanisms can be spliced into the contour shape of the car door cover, which is used for the wrapping of the car door cover.
  • the knife-pressing mechanism includes a bottom plate, a knife-pressing base, a linear drive unit, and a pre-wrapping press knife and a lower-layer final hemming press knife disposed on the upper side of the lateral side of the knife-pressing base.
  • both the pre-wrapping press knife and the final hemming press knife are formed by splicing several sections of press knife blades.
  • the knife pressing mechanism further includes a self-locking mechanism for restricting the movement of the bottom plate.
  • the jacking mechanism includes a drive base, a servo motor, a ball screw, a jacking block, and symmetrically arranged left wedge blocks and right wedge blocks.
  • the left wedge-shaped block and the right wedge-shaped block are respectively provided with rollers
  • the lifting block has a bottom inclined surface matched with the left wedge-shaped block and the right wedge-shaped block respectively
  • the bottom inclined surface includes For the pre-wrapping surfaces at both ends, the final wrapping surface, and the fast-travel surface in the middle, the inclination angle of the quick-travel surface is greater than the inclination angle of the pre-edge wrapping surface and the final wrapping surface.
  • the bottom inclined front side of the lifting block is provided with a guide rail plate, and the guide rail plate is a three-section guide rail;
  • the inclination angles of the pre-wrapped guide rail and the final edge-wrapped guide rail are respectively the same as the inclination angles of the pre-wrapped edge surface and the final edge-wrapped surface.
  • the compression molding mechanism includes an upper compression mold, an upper mold driving cylinder and a guide rod.
  • the upper die can be divided into several partitions, each partition is provided with a clamping block, and the several clamping blocks after the partition are annularly arranged on the bottom of the upper die along the edge of the door cover, and pass through the upper die.
  • the clamping cylinders are driven respectively, and a pressure sensor is arranged between the clamping block and the clamping cylinder.
  • the upper die driving cylinder is equipped with a pressure relief valve and a proportional valve.
  • the present invention also provides a highly flexible hemming method based on the segmented control principle, comprising the following steps:
  • the jacking mechanism drives the tire mold mounting seat, tire mold, press molding mechanism, and the car door cover to move to the pre-wrapping waiting station c at the same time, so that the edges around the car door cover are located on the lower side of the pre-wrapping press knife ;Then all the pressing knives are moved to the side of the tire mold under the drive of the linear drive unit, and all the pre-edge pressing knives are seamlessly spliced into the contour shape of the car door cover;
  • the jacking mechanism lifts the tire mold up to the pre-wrapping station b, and the pre-wrapping press knife bends the edge of the outer panel of the automobile door cover to complete the pre-wrapping; the jacking mechanism drives the tire mold to descend To the pre-wrapping waiting station c, all the pressing mechanisms are returned to the waiting station;
  • the lifting mechanism drives the tire mold to descend to the final hemming and waiting station e, and the press knife mechanism is pushed forward to the working position again, and the final hemming press knife is seamlessly spliced into a whole circle;
  • the jacking mechanism drives the tire mold to lift to the final hemming station d, and the edges around the car door cover are flattened under the extrusion of the final hemming knife; the jacking mechanism drives the tire mold to return to the final hemming Waiting for station e, the pressing mechanism returns to the waiting station again;
  • the lifting mechanism lifts the tire mold back to the upper part station a, and at the same time the pressing mold mechanism returns, and finally retrieves the car cover plate after hemming to complete the entire hemming process.
  • the highly flexible table-top hemming machine based on the segmented control principle of the present invention is provided with a press knife mechanism with a pre-wrapped press knife, a final hemmed press knife, and a tire mold that can move up and down, and the two cooperate with each other.
  • the hemming is performed in two steps, which can achieve high quality and high stability of the hemming; by setting replaceable tire molds, die pressing mechanisms, and pressing knife mechanisms, they can be individually designed according to different door cover parts, and the rest of the mechanisms can be used as standard Parts or semi-standard parts are used, and the mechanism has a high reuse rate.
  • the pressing mechanism can be adjusted and moved according to the size of the door cover and the shape of the edge contour, which has the advantage of high flexibility; in addition, the car door cover can complete the whole circle at one time when hemming. Therefore, the beat of the hemming is greatly accelerated, and the quality, stability and consistency of the hemming are greatly improved.
  • the highly flexible table-top hemming machine based on the segmented control principle of the present invention not only has the advantages of high quality and high stability of hemming, but also meets the flexibility and high rhythm required by the market to deal with different models, and also has a structural Compact and reasonable, low cost, small footprint, easy to find problems and simple maintenance and debugging, fully meet the current market demand and have a broad market space.
  • Fig. 1 is the structural representation of the highly flexible table-top hemming machine based on the segmented control principle of the present invention
  • FIG. 2 is a schematic diagram of the position of the tire mold in the hemming process in the highly flexible table hemming machine based on the segmented control principle of the present invention
  • Fig. 3 is the structural schematic diagram of the press knife mechanism in the highly flexible table-type hemming machine based on the segmented control principle of the present invention
  • FIG. 4 is a cross-sectional structural schematic diagram of the tire mold mounting seat in the highly flexible table-type hemming machine based on the segmented control principle of the present invention
  • Fig. 5 is the structural schematic diagram of the jacking mechanism in the highly flexible table hemming machine based on the segmented control principle of the present invention
  • FIG. 6 is a schematic structural diagram of a die mechanism in a highly flexible table-top hemming machine based on the segmented control principle of the present invention
  • Fig. 7 is the structural schematic diagram of the turning mechanism in the highly flexible table-top hemming machine based on the segmented control principle of the present invention
  • FIG. 8 is a schematic structural diagram of the cooperation between the press knife mechanism and the tire mold in the highly flexible table-type hemming machine based on the segmented control principle of the present invention
  • FIG. 9 is a schematic diagram 1 of the pre-edging of the highly flexible table-top hemming machine based on the segmented control principle of the present invention.
  • FIG. 10 is a schematic diagram 2 of the pre-edging of the highly flexible table-top hemming machine based on the segmented control principle of the present invention
  • FIG. 11 is a schematic diagram 1 of the final hemming of the highly flexible table top hemming machine based on the segmented control principle of the present invention
  • FIG. 12 is a schematic diagram 2 of the final hemming of the highly flexible table top hemming machine based on the segmented control principle of the present invention
  • FIG. 13 is a partial cross-sectional view of the die mechanism in the highly flexible table-top hemming machine based on the segmented control principle of the present invention
  • FIG. 14 is a schematic structural diagram of a clamping cylinder in the highly flexible table top hemming machine based on the segmented control principle of the present invention
  • Fig. 15 is a schematic diagram of dividing the upper die into several clamping blocks in the highly flexible table-top hemming machine based on the segmented control principle of the present invention
  • 16 is a schematic structural diagram of the self-locking mechanism in the highly flexible table-top hemming machine based on the segmented control principle of the present invention
  • 17 is a schematic structural diagram of a guide rail plate in a highly flexible table-top hemming machine based on the segmented control principle of the present invention.
  • FIG. 18 is a cross-sectional view of the cooperation between the left wedge block and the lead screw in the highly flexible table-top hemming machine based on the segmented control principle of the present invention.
  • Knife-pressing mechanism 2. Tire mold; 3. Lifting mechanism; 4. Tire mold mounting seat; 5. Base; 6. Molding mechanism; 7. Turning mechanism; 8. Pre-wrapping knife; 9. Final 10. Adjustable gasket; 11. Base; 12. Bottom plate; 13. Front pressure plate; 14. Both side pressure plates; 15. Self-locking mechanism; 16. Linear drive unit; 17. Limit screw ;
  • a highly flexible desktop hemming machine based on the principle of segmented control includes: a base 5 , a tire mold mounting seat 4 , a jacking mechanism 3 , and a tire mold set on the tire mold mounting seat 4 2.
  • Several pressing mechanisms 1 located around the tire mold 2, a pressing mechanism 6 located on the upper side of the tire mold 2, and a turning mechanism 7 that drives the pressing mechanism 6 to rotate, wherein the jacking mechanism 3 It is used to drive the tire mold mounting seat 4 and the tire mold 2 to slide in the vertical direction in the base 5 .
  • the outer plate and inner plate of the automobile door cover are placed on the tire mold 2, and the outer plate is fixed by the outer plate positioning mechanism on the tire mold 2, and the pressing mechanism 6 is driven by the overturning mechanism 7 to be turned over to the working position,
  • the die pressing mechanism 6 is pressed to the inner plate by the cylinder, so far the inner plate and the outer plate are both positioned and clamped, and then moved horizontally by the pressing knife mechanism 1, and the pressing knife mechanism 1 cooperates with the tire mold 2 to complete the pre-pressing and Final compression to achieve the edge of the door cover.
  • the knife pressing mechanism 1 has two upper and lower laminating knives, which are the pre-wrapping knives 8 of the upper layer and the final hemming knives 9 of the lower layer, the pre-wrapping knives 8 and the final hemming knives, respectively.
  • the press knives 9 are all mounted on the triangular press knife base 11 , and the press knife base 11 is integrally cast.
  • the pre-wrapped press knife 8 and the final hemmed press knife 9 are formed by splicing several segments of press-knife blades 41, and each segment of press-knife blade 41 is provided with an adjustable gasket 10 above.
  • the adjustable gasket 10 is used to adjust the position of the pressure knife blade 41 in the height direction.
  • the shape of each section of the pressure knife blade 41 is not exactly the same.
  • the contours are matched, all the pre-wrapping press knives 8 and the final hemming press knives 9 can form a circle after splicing, and their shape matches the outer contour of the entire door cover. With the movement of the edge pressing knife 9, the car door cover can complete the whole circle of edging at one time, so the rhythm of the edging is greatly accelerated, and the quality, stability and consistency of the edging are greatly improved.
  • a single knife-pressing mechanism is equipped with a plurality of segmented knife-pressing blades 41.
  • each knife-pressing blade may have an angular deviation in the front-rear direction due to the shape of the door cover, the knife-pressing blade is installed
  • the installation height of the surface in the vertical direction is the same. But there are other situations. When the height deviation of a certain position of the door cover is larger than that of other positions, that is, a certain position of the door cover is upturned. In this case, the pressure knife blade 41 corresponding to the upturned position needs to be adjusted in relative position. Adjustment will result in that the installation surfaces of several sections of the vertical direction of the pressing knife of the same layer of a single pressing knife mechanism are not at the same height, and there will be mutual staggering or angular deviation, so as to adapt to the shape of the door cover.
  • the lower side of the bottom plate 12 is provided with a linear drive unit 16, the piston rod part of the linear drive unit 16 is fixedly connected to the bottom plate 12, the cylinder part is fixedly connected to the frame, and the linear drive unit 16 drives the bottom plate 12 and the upper mechanism along both sides.
  • the pressing plate 14 reciprocates back and forth.
  • the front part of the bottom plate 12 is provided with a front side pressing plate 13, and the front side pressing plate 13 is pressed on the bottom plate 12, which further reduces the overall stress and deformation of the pressing knife base 11 during hemming.
  • the surface is in contact with the jacking mechanism during hemming and acts as a limit surface.
  • a self-locking mechanism 15 is also fixedly installed on the rack.
  • the self-locking mechanism 15 is located on the lower side of the bottom plate 12 .
  • the self-locking mechanism 15 has a self-locking shaft, which can be inserted and matched with the bottom plate 12 to limit the bottom plate 12 . Move, when the pre-wrapping knife 8 or the final hemming knife 9 moves to the hemming station, the self-locking mechanism 15 will start immediately, and the knife-pressing mechanism 1 will be locked and fixed to prevent the knife from moving back and forth. And cause the edge quality problem.
  • the self-locking mechanism 15 includes a cylinder, a self-locking shaft 152, and a shaft sleeve 151.
  • the cylinder and the shaft sleeve 151 are fixed on the frame of the hemming equipment, and the self-locking shaft 152 is driven by the air cylinder on the shaft sleeve.
  • 151 reciprocates up and down, the rear end of the bottom plate 12 has an inclined surface, and the upper end of the self-locking shaft 152 also has an inclined surface.
  • the self-locking function can also be realized by adjusting the displacement of the cylinder, that is to say, the same self-locking mechanism 15 can satisfy the self-locking of multiple different working positions of the knife pressing mechanism 1 .
  • Backward component force in this case, the self-locking mechanism 15 is definitely not required; the size of the component force is determined by the angle of the working face of the pre-pressing knife and the length of the working face. If the component force is smaller than the cylinder thrust, in this case There is also no need for a self-locking device. Because the working surface of the press knife is quite complex, the component force is difficult to calculate clearly, so in many cases it is impossible to judge the relationship between the component force and the thrust of the cylinder. The installation position of the lock mechanism 15 in case of emergency.
  • the knife-pressing base 11 is fixedly installed on the bottom plate 12 , the top, bottom and left and right sides of the bottom plate 12 are provided with self-lubricating plates with graphite, and both sides of the rear of the bottom plate 12 are provided with two sides
  • the pressure plate 14, the two side pressure plates 14 are fixedly connected with the frame of the whole hemming equipment, and the two side pressure plates 14 are used to limit the movement direction of the pressure knife base 11.
  • a limit screw 17 is installed between the knife press base 11 and the front side press plate 13 , and an adjusting washer is also provided, so that the front and rear positions of the knife press base 11 can be finely adjusted.
  • a position sensor 18 is provided at the bottom of the knife-pressing base 11 , and the position sensor 18 can sense the position of the knife-pressing mechanism 1 .
  • the base 5 is provided with through holes for facilitating the movement of the tire mold mounting seat 4 in the vertical direction, and the four diagonal corners of the through holes are designed with vertical grooves, which are lubricated by brass and solid
  • the guide rail 21 made of chemical graphite is installed in the four grooves of the base 5, and the corresponding positions of the four diagonal corners of the tire mold mounting base 4 are also designed with grooves, the width of which is the same as that of the guide rail 21.
  • the jacking mechanism 3 includes a drive base 22 , a servo motor 29 , a ball screw 24 , a left wedge block 25 , a right wedge block 26 , and a jacking block 23 .
  • the drive base 22 is a casting with a certain rigidity, and has bearing holes at both ends for installing the ball screw 24.
  • the ball screw is driven by a servo motor 29, and the servo motor 29 is connected to the drive base 22 through a flange.
  • the ball screw 24 is connected to it through the hollow shaft of the servo motor 29, and the servo motor 29 is equipped with a servo driver, which can precisely control its parameters such as rotation speed and output torque.
  • the ball screw 24 has left-hand and right-hand threads, and is equipped with two nuts, left-hand and right-hand.
  • the left-hand nut is installed in the left wedge block 25, the right-hand nut is installed in the right wedge block 26.
  • the block 25 and the right wedge-shaped block 26 are both wedge-shaped sliders with an inclined surface on the upper part, both of which are inclined downward along the inner side, and the two inclined directions are arranged symmetrically;
  • the lifting block 23 is arranged on the upper side of the left wedge-shaped block 25 and the right wedge-shaped block 26.
  • the lower part of the jacking block 23 has two symmetrically arranged bottom slopes, and the slope angle of the bottom slope is the same as that of the left wedge block 25 and the right wedge block 26.
  • the left and right wedge blocks 25 and the right wedge block 26 are driven by the left and right wedge blocks 25 to move in opposite directions or in opposite directions, thereby driving the lift block 23 to move vertically up and down, thereby pushing The tire mold 2 on the upper side of the jacking mechanism moves up and down to complete the hemming process.
  • a pressure sensor 28 is arranged between the jacking block 23 and the tire mold mounting seat 4, which can timely feedback the force provided by the jacking mechanism 3 to the tire mold 2, so that an appropriate force can be selected to meet the hemming requirements. , to improve the quality of edging.
  • the die mechanism 6 includes an upper die 36 , an upper die driving cylinder 34 and a guide rod 35 .
  • the upper die 36 is driven by the upper die driving cylinder 34 to move vertically up and down along the guide rod 35.
  • the upper die 36 cooperates with the tire mold 2 to compress the door cover.
  • the upper mold driving cylinder 34 is equipped with a pressure relief valve. During the entire hemming process, the upper mold 36 will move with the movement of the tire mold 2, and the pressure between the two remains unchanged.
  • the mechanism 6 is equipped with a proportional valve, and the output pressure of the upper die driving cylinder 34 can be controlled by adjusting the proportional valve.
  • the upper die 36 can be divided into several partitions, each partition is provided with a clamping block 361, and the several clamping blocks 361 after the partition are annularly arranged along the edge of the door cover
  • the bottom of the upper die 36 is driven by the clamping cylinders 39 respectively.
  • a pressure sensor 40 is arranged between the clamping blocks 361 and the clamping cylinders 39, so that the clamping blocks 361 in each partition are with their respective suitable clamping pressures.
  • the pressure sensor 40 is installed between the zone clamping block 361 and the clamping cylinder 39 to measure the actual pressure on the body panels in each area, and adjust the output pressure of the clamping cylinder 39 according to the difficulty of wrapping the body panels in different areas. , to avoid problems such as overpressure or insufficient pressure on the body panels.
  • the turning mechanism 7 is composed of a servo motor 37 and a link mechanism 38.
  • the servo motor 37 drives the link mechanism 38 to drive the die mechanism 6 to turn over.
  • the linkage mechanism is exactly three points and one line, forming a dead center mechanism.
  • both sides of the lifting block 23 are provided with lifting guide plates 31 , and the lifting guide plate 31 is provided with a V-shaped groove, and the lifting block 23 is correspondingly designed with a V-shaped protrusion. , Under the cooperation of the V-shaped bump and the V-shaped groove, it can play a guiding role when the lifting block 23 moves up and down, preventing the lifting block 23 from moving to one side when the left wedge block 25 and the right wedge block 26 move out of sync. stray.
  • the jacking mechanism also has a design of rapid travel
  • the two-stage bottom slope of the jacking block 23 is designed as a three-stage type, and the bottom slope includes the pre-wrapped edge surface 231,
  • the quick travel surface 232, the final wrapping surface 233, the pre wrapping surface 231 and the final wrapping surface 233 are inclined surfaces with two key forces (pre wrapping and final wrapping), and the inclination of the quick travel surface 232 is greater than that of the pre wrapping
  • the slope of the edge surface 231 and the final wrap edge surface 233 is designed as a three-stage type, and the bottom slope includes the pre-wrapped edge surface 231,
  • the quick travel surface 232, the final wrapping surface 233, the pre wrapping surface 231 and the final wrapping surface 233 are inclined surfaces with two key forces (pre wrapping and final wrapping), and the inclination of the quick travel surface 232 is greater than that of the pre wrapping
  • the slope of the edge surface 231 and the final wrap edge surface 233 are inclined surfaces with two key forces (pre wrapping and final wrapping),
  • a guide rail plate 27 is added to the front side of the jacking block 23.
  • the guide rail plate 27 also has two symmetrical three-segment guide rails.
  • the inclination of the quick travel guide rail 272 in the middle of the plate 27 is greater than the inclination of the pre-wrapping guide rail 271 and the final hemming guide rail 273 at both ends of the guide rail plate 27, while the pre-wrapping guide rail 271 and the final hemming guide rail 273 at both ends of the guide rail
  • the inclination is the same as the inclination of the pre-edge surface 231 and the final edge surface 233 of the jacking block 23 .
  • the roller 30 is installed on the left wedge block 25 and the right wedge block 26.
  • the lifting block 23 can be quickly lifted up to complete the emptying.
  • the bottom surface of the jacking block 23 contacts with the wedge block and receives force, and returns to a state that can bear a large load.
  • the roller 30 When the load of the free-travel system is small, the roller 30 is in contact with the fast-travel guide rail to realize the rapid lifting and lowering of the jacking block; in the pre-edging and final-edging, the bottom of the jacking block and the wedge block are contacted and stressed to withstand large load pressure , to realize the lifting movement of the lifting block.
  • the hemming cycle can be improved.
  • the drive base 22 is provided with an oil pump 32 and a drag chain 33 , the oil pump 32 is located at one end of the ball screw 24 , the oil pipe is connected to the left and right nuts through the drag chain 33 , and the oil pump 32 can be periodically moved to the left and right through the oil pipe.
  • Ball screw 24 and nut supply oil to improve lubrication conditions and prolong service life.
  • a highly flexible hemming method based on a segmented control principle comprising the following steps:
  • the jacking mechanism 3 drives the tire mold mounting seat 4, the tire mold 2, the press molding mechanism 6, and the automobile door cover to move to the pre-wrapping waiting station c at the same time, so that the edges around the automobile door cover are located in the pre-wrapping.
  • the jacking mechanism 3 lifts the tire mold 2 up to the pre-wrapping station b, and the pre-wrapping press knife 8 bends the edge of the outer panel of the automobile door cover to complete the pre-wrapping; the jacking mechanism 3 drives the The tire mold 2 is lowered to the pre-wrapping waiting station c, and the pressing mechanism 1 is all returned to the waiting station;
  • the lifting mechanism 3 drives the tire mold 2 to descend to the final hemming and waiting station e, and the pressing knife mechanism 1 is pushed forward to the working position again, and the final hemming and pressing knife 9 is seamlessly spliced into a whole circle;
  • the jacking mechanism 3 drives the tire mold 2 to lift the tire mold 2 to the final hemming station d, and the edges around the door cover of the automobile are flattened under the extrusion of the final hemming knife 9 to complete the final hemming; the jacking mechanism 3. Drive the tire mold 2 to return to the final wrapping and waiting station e, and the pressing mechanism 1 returns to the waiting station again;
  • the lifting mechanism 3 lifts the tire mold 2 back to the upper work station a, and at the same time, the pressing mechanism 6 returns, and finally retrieves the edge-wrapped automobile cover to complete the entire hemming process.
  • the robot grabs the door cover to be wrapped and puts it into the tire mold 2.
  • the tire mold 2 includes an outer plate positioning mechanism.
  • the outer plate positioning mechanism positions and tightens the outer plate.
  • the servo motor 37 and the connecting rod The turning mechanism 7 driven by the mechanism 38 is turned over to the working position, and the upper die mechanism 6 is pressed to the inner plate by the upper die driving cylinder 34, so far both the inner and outer plates are positioned and clamped;
  • the lifting mechanism 3 composed of the ball screw 24 and the wedge-shaped slider drives the tire mold mounting seat 4 and the tire mold 2 to move.
  • the tire mold mounting seat 4 and the tire mold 2 are lowered from the upper part station a to the pre-wrapping waiting station c.
  • the pressing knife mechanism 1 is pushed forward to the hemming working position, at this time all the pre-wrapping pressing knives 8 are seamlessly spliced together to form a whole circle (as shown in Figure 8).
  • the lifting mechanism 3 lifts the tire mold 2 to the pre-wrapping station b, and the pre-wrapping knives 8 bend the edges of the car door cover (as shown in Figure 10). shown) to complete the pre-wrapping process.
  • the jacking mechanism 3 drives the tire mold 2 to return to the pre-wrapping waiting station c, and then the pressing mechanism 1 all returns to the waiting position, and the jacking mechanism 3 drives the tire mold 2 to descend to the final hemming waiting position.
  • the pressing knife mechanism 1 is pushed forward to the working position again, the final hemming press knife 9 is seamlessly spliced into a whole circle, and the jacking mechanism 3 drives the tire mold 2 to lift the final hemming machine.
  • the edge of the door cover is flattened by the final edge pressing knife 9 (as shown in Figure 12).
  • the lifting mechanism 3 drives the tire mold 2 to return to the final hemming waiting station e, the knife press mechanism 1 returns to the waiting station again, and the jacking mechanism 3 lifts the tire mold 2 back to the upper part position. a.
  • the die pressing mechanism 6 is retracted, the turning mechanism 7 is driven by the motor to open to the waiting station, the robot enters the equipment again, and grabs the door cover after the hemming is completed and leaves the station. So far, a complete hemming cycle is completed. finished.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Perforating, Stamping-Out Or Severing By Means Other Than Cutting (AREA)
  • Automobile Manufacture Line, Endless Track Vehicle, Trailer (AREA)

Abstract

本发明公开了一种基于分段控制原理的高柔性桌式包边机，包括底座、胎模安装座、顶升机构、胎模、若干压刀机构、位于胎模上侧的压模机构、以及翻转机构；其中，顶升机构用于带动胎模及门盖件上下移动，压刀机构驱动压刀水平运动对门盖件进行包边；而若干组压刀机构能拼接成汽车门盖件轮廓形状，用于汽车门盖件的包边。本发明还公开了一种基于分段控制原理的高柔性包边方法，包括预包边和终包边等步骤。本发明的包边机不仅具备包边高质量、高稳定性的优势，同时也满足市场应对不同车型所需要的柔性及高节拍，并且还具有结构紧凑合理、低成本，占地小，容易发现问题且维护调试简单等优势，完全满足目前的市场需求，具有广阔的市场空间。

Description

一种基于分段控制原理的高柔性桌式包边机及包边方法 技术领域
本发明涉及钣金加工设备技术领域，具体涉及一种基于分段控制原理的高柔性桌式包边机和包边方法。
背景技术
汽车的四门两盖是汽车车身总成的重要组成部分，由于其需要开闭的特性，四门两盖的边需要美观圆滑，因此包边工艺相对于焊接、铆接等连接工艺，对于四门两盖来说是不可取代的。
近年来，随着现代汽车车型的愈益多样化和个性化，对包边工艺的质量要求和复杂程度也日益提升，另外，对于各大主机厂投放的“走量”车型，其除了质量方面和外观方面的要求外，其极高的生产节拍也对目前的包边工艺提出了挑战。
目前汽车门盖件的包边方法占据主流的为压机包边和机器人滚边，机器人滚边系统主要由滚边夹具、滚边工具、机器人及其控制系统构成，其原理是利用滚轮对门盖件翻边进行多次滚压，以达到外板包住内板的目的，其优点是柔性高、调试灵活，其缺点一是滚边速度慢，节拍一般不超50JPH，二是长期的质量稳定性不高，需要人为的维护和修正较多。
压机包边主要由压力主体加可切换的包边模具构成，其原理是利用上模和下模的扣合，完成预翻边和终包边，达到外板包住内板的目的，其优点是包边速度快、包边质量稳定，缺点是占地面积大、柔性差、成本高，尤其是在多车型共线的项目中，需要增加模具切换轨道，增加了车型切换的时间并且投入成本极高，其中老式的液压压机还有噪音大、油污染等缺陷，不能顺应目前节能减排的趋势。
如专利US20080302161A1公开的一种包边设备和方法，其升降机构主要采用气缸、连杆、凸轮机构来实现往复式升降功能，配合压刀机构，板件固定机构来实现包边，该升降结构较为复杂，能够承受的负载相对较小，对于升降行程控制困难，稳定性差，此外，其压刀机构结构简单，难以匹配多车型不同板件，兼容性相对差。
专利CN203265351U公开的一种汽车车门的包边机，通过滚珠丝杆把电机输出扭矩转化成螺母座向前的推力，螺母座带动连杆二与连杆三围绕各自另一支点转动，连杆二与连杆三绕支点转动同时，分别推动连杆一与连杆五围绕其在主体框架上的支点转动，通过连杆二与连杆三组成的増力铰链完成増力过程，即利用滚珠丝杠和多连杆 机构来实现包边的推力，作用于压刀机构，但上述结构能承受的负载范围较小，稳定性差，且该压刀机构较小，主要适用于一些狭小空间部分的包边，对于整个门盖件的包边一致性相对较差。
发明内容
为克服现有技术的缺陷，本发明的目的在于提供一种基于分段控制原理的高柔性桌式包边机，以实现汽车门盖件的快速、稳定包边。
为此，本发明提出了一种基于分段控制原理的高柔性桌式包边机，包括底座、胎模安装座、顶升机构、胎模安装座上设置的胎模、位于胎模四周的若干压刀机构、位于胎模上侧的压模机构、以及驱动压模机构转动的翻转机构；其中，顶升机构用于带动胎模及门盖件上下移动，压刀机构驱动压刀水平运动对门盖件进行包边；而若干组压刀机构能拼接成汽车门盖件轮廓形状，用于汽车门盖件的包边。即利用多组压刀根据加工门盖件的轮廓形状环形围绕布置，实现对门盖件的一次性整圈包边，该设计具有提高生产节拍，工艺一致性好的优点。
进一步地，所述压刀机构包括底板、压刀基座、直线驱动单元、以及设置在所述压刀基座侧边上层的预包边压刀和下层的终包边压刀。
进一步地，所述预包边压刀和所述终包边压刀都由若干段压刀刀片拼接而成。
进一步地，所述压刀机构还包括自锁机构，用于限制所述底板移动。
进一步地，所述顶升机构包括驱动基座、伺服电机、滚珠丝杠、顶升块、以及对称设置的左楔形块和右楔形块。
进一步地，所述左楔形块和所述右楔形块上分别设有滚轮，所述顶升块具有分别与所述左楔形块和所述右楔形块相配合的底部斜面，所述底部斜面包括两端的预包边面、终包边面、以及中间的快速行程面，所述快速行程面的倾斜角度大于所述预包边面和所述终包边面的倾斜角度。
所述顶升块的底部斜面前侧设有导轨板，所述导轨板为三段式导轨；所述三段式导轨包括预包边导轨、快速行程导轨以及终包边导轨，且所述的预包边导轨、终包边导轨的倾斜角度分别与所述的预包边面、终包边面的倾斜角度对应相同。
进一步地，所述压模机构包括上压模、上模驱动气缸和导向杆。
进一步地，所述上压模能分成若干个分区，每个分区设置一个夹紧块，分区后的若干所述夹紧块沿门盖件的边环形设置在所述上压模底部，并通过夹紧气缸分别驱动，且所述夹紧块与所述夹紧气缸之间设有压力传感器。
进一步地，所述上模驱动气缸配有泄压阀和比例阀。
本发明还提供一种基于分段控制原理的高柔性包边方法，包括如下步骤：
S1、通过顶升机构驱动胎模至上件工位a，并将汽车门盖件放入胎模，胎模对汽车门盖件外板进行固定，压模机构对汽车门盖件内板进行固定；
S2、顶升机构驱动胎模安装座、胎模、压模机构、以及汽车门盖件同时移动至预包边等待工位c，使汽车门盖件四周的边位于预包边压刀下侧；然后所有压刀机构在直线驱动单元驱动下向胎模一侧移动，且所有预包边压刀都被无缝拼接成汽车门盖件轮廓形状；
S3、顶升机构将胎模向上顶升至预包边工位b，预包边压刀将汽车门盖件外板的边折弯，完成预包边；顶升机构驱动所述胎模下降至预包边等待工位c，所述压刀机构全部退回至等待工位；
S4、顶升机构驱动胎模下降至终包边等待工位e,压刀机构再次前推至工作位，终包边压刀无缝拼接成整圈；
S5、顶升机构驱动胎模顶升至终包边工位d，汽车门盖件四周的边在终包边压刀的挤压下被压平；顶升机构驱动胎模退回到终包边等待工位e，压刀机构再次退回至等待工位；
S6、顶升机构顶升胎模回到上件工位a，同时压模机构退回，最后取回包边后的汽车盖板，完成整个包边工序。
与现有技术相比，本发明的有益效果：
1、本发明的基于分段控制原理的高柔性桌式包边机，通过设置具有预包边压刀、终包边压刀的压刀机构、能上下移动的胎模，通过两者相互配合分两步进行包边，可以实现包边的高质量、高稳定性；通过设置可更换的胎模、压模机构、压刀机构，可根据不同门盖件单独设计，其余机构都可作为标准件或者半标准件使用，机构重复利用率高，压刀机构可根据门盖件大小和边缘轮廓形状调节移动，具有高柔性优点；此外，汽车门盖件在包边时能一次性完成整圈包边，因此包边的节拍大大加快，包边质量、稳定性、一致性大大提升。
2、本发明的基于分段控制原理的高柔性桌式包边机不仅具备包边高质量、高稳定性的优势，同时也满足市场应对不同车型所需要的柔性及高节拍，并且还具有结构紧凑合理、低成本，占地小，容易发现问题且维护调试简单等优势，完全满足目前的市场需求，具有广阔的市场空间。
除了上面所描述的目的、特征和优点之外，本发明还有其它的目的、特征和优点。下面将参照图，对本发明作进一步详细的说明。
附图说明
构成本申请的一部分的说明书附图用来提供对本发明的进一步理解，本发明的示意性实施例及其说明用于解释本发明，并不构成对本发明的不当限定。在附图中：
图1为本发明的基于分段控制原理的高柔性桌式包边机的结构示意图；
图2为本发明的基于分段控制原理的高柔性桌式包边机中包边过程的胎模位置示意图；
图3为本发明的基于分段控制原理的高柔性桌式包边机中压刀机构处的结构示意图；
图4为本发明的基于分段控制原理的高柔性桌式包边机中胎模安装座处的剖视结构示意图；
图5为本发明的基于分段控制原理的高柔性桌式包边机中顶升机构的结构示意图；
图6为本发明的基于分段控制原理的高柔性桌式包边机中压模机构的结构示意图；
图7为本发明的基于分段控制原理的高柔性桌式包边机中翻转机构的结构示意图；
图8为本发明的基于分段控制原理的高柔性桌式包边机中压刀机构与胎模配合的结构示意图；
图9为本发明的基于分段控制原理的高柔性桌式包边机预包边示意图一；
图10为本发明的基于分段控制原理的高柔性桌式包边机预包边示意图二；
图11为本发明的基于分段控制原理的高柔性桌式包边机终包边示意图一；
图12为本发明的基于分段控制原理的高柔性桌式包边机终包边示意图二；
图13为本发明的基于分段控制原理的高柔性桌式包边机中压模机构的部分剖视图；
图14为本发明的基于分段控制原理的高柔性桌式包边机中夹紧气缸的结构示意图；
图15为本发明的基于分段控制原理的高柔性桌式包边机中上压模分成若干夹紧块的示意图；
图16为本发明的基于分段控制原理的高柔性桌式包边机中自锁机构的结构示意图；
图17为本发明的基于分段控制原理的高柔性桌式包边机中导轨板的结构示意图；以及
图18为本发明的基于分段控制原理的高柔性桌式包边机中左楔形块与丝杠配合的剖视图。
附图标记说明
1、压刀机构；2、胎模；3、顶升机构；4、胎模安装座；5、底座；6、压模机构；7、翻转机构；8、预包边压刀；9、终包边压刀；10、可调垫片；11、基座；12、底板；13、前侧压板；14、两侧压板；15、自锁机构；16、直线驱动单元；17、限位螺钉；
18、位置传感器；21、导轨；22、基座；23、顶升块；24、滚珠丝杠；25、左楔形块；26、右楔形块；27、导轨板；28、压力传感器；29、伺服电机；30、滚轮；31、升降导向板；32、油泵；33、拖链；34、上模驱动气缸；35、导向杆；36、上压模；
37、伺服电机；38、连杆机构；39、夹紧气缸；40、压力传感器；41、压刀刀片；151、轴套；152、自锁轴；231、预包边面；232、快速行程面；233、终包边面；271、预包边导轨；272、快速行程导轨；273、终包边导轨；361、夹紧块。
具体实施方式
需要说明的是，在不冲突的情况下，本申请中的实施例及实施例中的特征可以相互组合。下面将参考附图并结合实施例来详细说明本发明。
图1-图18示出了根据本发明的一些实施例。
如图1所示，一种基于分段控制原理的高柔性桌式包边机，包括：底座5、胎模安装座4、顶升机构3、所述胎模安装座4上设置的胎模2、位于所述胎模2四周的若干压刀机构1、位于所述胎模2上侧的压模机构6、以及驱动压模机构6转动的翻转机构7，其中，所述顶升机构3用于驱动所述胎模安装座4和胎模2在所述底座5内沿竖直方向滑动。
其中，汽车门盖件的外板和内板件均放置在胎模2上，并通过胎模2上的外板定位机构固定外板，通过翻转机构7驱动压模机构6翻转到工作位置，压模机构6通过气缸压紧到内板上，至此内板、外板均被定位夹紧，再通过压刀机构1水平移动，压刀机构1与胎模2配合完成外板的预压和最终压紧，实现门盖的包边。
具体地，如图3所示，压刀机构1具有上下两层压刀，分别为上层的预包边压刀8和下层的终包边压刀9，预包边压刀8和终包边压刀9均安装于三角形的压刀基座11上，而压刀基座11整体铸造而成。
其中，如图3、8所示，预包边压刀8和终包边压刀9都由若干段压刀刀片41拼接而成，每段压刀刀片41上方都装有可调垫片10，可调垫片10用于调节压刀刀片41高度方向的位置，每段压刀刀片41的刀头形状不完全相同，若干段压刀刀片41拼接后能与对应位置的门盖件的外轮廓相匹配，所有预包边压刀8和终包边压刀9拼接完成后能围成一圈，其形状与整个门盖件的外轮廓相匹配，通过预包边压刀8或终包边压刀9的运动，汽车门盖件在包边时能一次性完成整圈包边，因此包边的节拍大大加快，包边质量、稳定性及一致性大大提升。
如图8所示，本发明中单个压刀机构都配有分段的多个压刀刀片41，虽然每个压刀刀片在前后方向可能因门盖件造型原因存在角度偏差，但是压刀安装面在竖直方向的安装高度都是一致的。但也会存在其他情况，当门盖件某处位置相对其他位置而言高度偏差较大，即门盖件某位置上翘，这样的话上翘位置对应的压刀刀片41则需要进行相对位置的调整，从而导致单个压刀机构同一层的几段压刀竖直方向的压刀安装面不在同一高度，出现相互错开或者角度偏差的情况，以适应门盖件造型。
所述底板12下侧设有直线驱动单元16，直线驱动单元16的活塞杆部分与底板12固定连接，缸体部分与机架固定连接，直线驱动单元16驱动底板12及上部的机构沿两侧压板14前后往复运动。其中，底板12前部设有前侧压板13，前侧压板13压在底板12上，进一步减小了压刀基座11在包边时的整体受力变形，同时底板12的伸出部位下表面在包边时与顶升机构互相接触，充当了限位面的功能。
具体地，机架上还固定安装有自锁机构15，自锁机构15位于底板12下侧，自锁机构15具有自锁轴，自锁轴能与底板12插接配合，用于限制底板12移动，当预包边压刀8或终包边压刀9移动到包边工位时，自锁机构15将会立刻启动，压刀机构1将会被锁死固定，防止压刀前后窜动而造成包边质量问题。
其中，如图16所示，自锁机构15包括气缸、自锁轴152、以及轴套151，气缸和轴套151固定在包边设备的机架上，由气缸驱动自锁轴152在轴套151中上下往复运动，底板12后端具有倾斜面，自锁轴152上端也具有倾斜面，自锁轴152与底板12通过倾斜面互相配合，倾斜面角度满足机械自锁角原理。其中，如果压刀机构1前后工作位置变化，同样可通过调整气缸位移量实现自锁功能，也就是说，同一自锁机构15可满足压刀机构1多个不同工作位置的自锁。
在本实施例中，并非所有的压刀机构1都需要配备自锁机构15，在某些特定条件下，如预压刀面角度水平或斜向下时，压刀机构不会受到沿驱动方向向后的分力，此情况是肯定不要自锁机构15的；分力的大小是由预压刀工作面角度的大小以及工作面的长度共同决定，若分力小于气缸推力，这种情况下也是不需要自锁装置的，由于压刀工作面相当复杂，分力难以明确计算，因此很多情况下无法判断分力与气缸推力的大小关系，此时就需要在压刀机构1上预留自锁机构15的安装位置，以备不时之需。
具体地，如图3所示，压刀基座11固定安装在底板12上，底板12的上下及左右侧面上都配有带有石墨的自润滑板，底板12后部两侧设有两侧压板14，两侧压板14与整个包边设备的机架固定连接，两侧压板14用于限制压刀基座11的运动方向。
在压刀基座11与前侧压板13之间装有限位螺钉17，同时也配有调节垫片，可对压刀基座11的前后位置进行微调。压刀基座11底部设有位置传感器18，位置传感器18可感知压刀机构1的所处位置。
具体地，如图4所示，底座5设有方便胎模安装座4沿竖直方向移动的通孔，通孔的四个对角设计有竖直方向的凹槽，由黄铜和固体润滑剂石墨制成的导轨21安装在底座5的四个凹槽中，胎模安装座4的四个对角的相应位置同样设计有凹槽，其宽度与导轨21相同，当顶升机构3驱动胎模安装座4上下运动时，胎模安装座4的四个凹槽沿着导轨21上下滑动，其中的固体润滑剂石墨可保证其不间断的润滑，而无需定期润滑维护。
具体地，如图5、17、18所示，顶升机构3包括驱动基座22、伺服电机29、滚珠丝杠24、左楔形块25、右楔形块26、以及顶升块23。驱动基座22为具有一定刚性的铸造件，其两端有轴承孔，用于安装滚珠丝杠24，滚珠丝杠由伺服电机29驱动，伺服电机29通过法兰连接在驱动基座22上，滚珠丝杠24穿过伺服电机29的空心轴与其连接，伺服电机29配有伺服驱动器，可精确控制其转速、输出扭矩等参数。
其中，滚珠丝杠24具有左旋和右旋两段螺纹，同时其配有左旋和右旋两个螺母，左旋螺母安装在左楔形块25中，右旋螺母安装在右楔形块26中，左楔形块25和右楔形块26均为上部为斜面的楔形滑块，两者均沿内侧下方倾斜，且两者倾斜方向对称布置；顶升块23设置在左楔形块25和右楔形块26上侧，顶升块23的下部具有两段对称设置的底部斜面，底部斜面的倾斜角度与左楔形块25和右楔形块26相同，当顶升块23落在左楔形块25和右楔形块26上时，顶升块23底部能与左楔形块25和右楔形块26的倾斜表面完全贴合。
当滚珠丝杠24在伺服电机29的驱动下旋转时，左右两个螺母驱动左楔形块25和右楔形块26相向运动或反向运动，从而带动顶升块23上下竖直上下运动，进而推动顶升机构上侧的胎模2上下移动，以完成包边工序。
其中，在顶升块23与胎模安装座4之间设有压力传感器28，能及时反馈顶升机构3向胎模2提供的作用力，从而可以选着合适的作用力，满足包边要求，提高包边质量。
具体地，如图6所示，压模机构6包括上压模36、上模驱动气缸34和导向杆35。上压模36通过上模驱动气缸34驱动，沿导向杆35垂直上下运动，上压模36与胎模2相互配合压紧门盖件。
其中，上模驱动气缸34配有泄压阀，在整个包边过程中，上压模36会随着胎模2的移动而移动，且两者之间的压力始终保持不变，同时压模机构6配有比例阀，可通过调节比例阀控制上模驱动气缸34的输出压力。
其中，如图14、15所示，所述上压模36能分成若干个分区，每个分区设置一个夹紧块361，分区后的若干所述夹紧块361沿门盖件的边环形设置在所述上压模36底部，并通过夹紧气缸39分别驱动，所述夹紧块361与所述夹紧气缸39之间设有压力传感器40，使得每个分区的所述夹紧块361具有各自适合的夹紧压力。
压力传感器40安装在分区夹紧块361与夹紧气缸39之间，用于测量各区域位置车身板件受到的实际压力，针对不同区域位置车身板件包边难度调整夹紧气缸39的输出压力，避免车身板件过压或者压不紧等问题。
具体地，如图7所示，翻转机构7由伺服电机37和连杆机构38构成，伺服电机37驱动连杆机构38从而驱动压模机构6进行翻转，当压模机构6运动至水平状态时，连杆机构恰好三点一线，形成死点机构。
在一实施例中，如图5，顶升块23的两侧设有升降导向板31，且升降导向板31上带有V型凹槽，顶升块23上相应的设计有V型凸块，在V型凸块和V型凹槽相互配合下，可在顶升块23上下运动时起导向作用，防止左楔形块25和右楔形块26移动不同步时，顶升块23向一侧跑偏。
在一实施例中，如图5、17、18所示，顶升机构还具有快速行程的设计，顶升块23的两段底部斜面设计为三段式，底部斜面包括预包边面231、快速行程面232、终包边面233，预包边面231和终包边面233为两个重点受力(预包边和终包边)的斜面，快速行程面232的斜度大于预包边面231和终包边面233的斜度。
顶升块23前侧增加了导轨板27，导轨板27也具有两段对称设置的三段式导轨，三段式导轨包括预包边导轨271、快速行程导轨272、终包边导轨273，导轨板27中部的快速行程导轨272的斜度大于导轨板27两端的预包边导轨271和终包边导轨273的斜度，而导轨板27两端的预包边导轨271和终包边导轨273的斜度与顶升块23的预包边面231和终包边面233的斜度相同。
如图2所示，滚轮30安装在左楔形块25和右楔形块26上，当滚轮30跟随左右楔块运动到快速行程导轨272处时，可将顶升块23快速的顶起，完成空行程的快速进给，当滚轮30脱离快速行程导轨272时，顶升块23的底面与楔形块接触受力，恢复到可承受大负载的状态。
在空行程系统负载较小时，滚轮30和快速行程导轨接触，实现顶升块快速升降；在预包边、终包边时，顶升块底部和楔形块接触受力，以承受大的负载压力，实现顶升块升降运动。通过快速行程结构的设计，可以提高包边节拍。
在一实施例中，如图5，驱动基座22上设有油泵32和拖链33，油泵32位于滚珠丝杠24一端，油管通过拖链33连接到左右螺母，油泵32通过油管可定期向滚珠丝杠24、螺母供油，以改善润滑条件，延长使用寿命。
一种基于分段控制原理的高柔性包边方法，包括如下步骤：
S1、通过顶升机构3驱动胎模2至上件工位a，并将汽车门盖件放入胎模2，胎模2对汽车门盖件外板进行固定，压模机构6对汽车门盖件内板进行固定；
S2、顶升机构3驱动胎模安装座4、胎模2、压模机构6、以及汽车门盖件同时移动至预包边等待工位c，使汽车门盖件四周的边位于预包边压刀8下侧；然后所有压刀机构1在直线驱动单元16驱动下向胎模2一侧移动，且所有预包边压刀8都被无缝拼接在一起围成一整圈，与汽车门盖件轮廓形状一致；
S3、顶升机构3将胎模2向上顶升至预包边工位b，预包边压刀8将汽车门盖件外板的边折弯，完成预包边；顶升机构3驱动所述胎模2下降至预包边等待工位c，所述压刀机构1全部退回至等待工位；
S4、顶升机构3驱动胎模2下降至终包边等待工位e,压刀机构1再次前推至工作位，终包边压刀9无缝拼接成整圈；
S5、顶升机构3驱动胎模2顶升至终包边工位d，汽车门盖件四周的边在终包边压刀9的挤压下被压平，完成终包边；顶升机构3驱动胎模2退回到终包边等待工位e，压刀机构1再次退回至等待工位；
S6、顶升机构3顶升胎模2回到上件工位a，同时压模机构6退回，最后取回包边后的汽车盖板，完成整个包边工序。
本发明的基于分段控制原理的高柔性桌式包边机的工作过程如下：
首先，机器人抓取准备包边的门盖件放入到胎模2中，胎模2中包含有外板定位机构，外板定位机构将外板定位并吸紧，由伺服电机37和连杆机构38驱动的翻转机构7翻转到工作位置，上压模机构6通过上模驱动气缸34压紧到内板上，至此内外板均被定位夹紧；汽车门盖件在胎模2中定位和固定后，由滚珠丝杠24和楔形滑块构成的顶升机构3驱动胎模安装座4和胎模2移动。
如图2所示，胎模安装座4及胎模2由上件工位a下降到预包边等待工位c，当胎模2达到预包边等待工位c时(如图9所示)，压刀机构1前推至包边工作位，此时所有预包边压刀8都被无缝拼接在一起围成一整圈(如图8所示)。预包边压刀8全部到达工作位置后，顶升机构3将胎模2顶升到预包边工位b，预包边压刀8将汽车门盖件的边折弯(如图10所示)，完成预包边工序。
完成预包边的动作后顶升机构3驱动胎模2退回预包边等待工位c，而后压刀机构1全部退回至等待工位，顶升机构3驱动胎模2下降至终包边等待工位e(如图11所示)，压刀机构1再次前推至工作位，终包边压刀9无缝拼接成整圈，顶升机构3驱动胎模2顶升至终包边工位d，门盖件的边在终包边压刀9的挤压下被压平(如图12所示)。
终包边完成后，顶升机构3驱动胎模2退回到终包边等待工位e，压刀机构1再次退回打开至等待工位，顶升机构3顶升胎模2回到上件位a，同时，压模机构6退回，翻转机构7由电机带动打开至等待工位，机器人再次进入设备，抓取包边完成后的门盖件离开工位，至此，一个完整的包边循环就完成了。
以上所述仅为本发明的优选实施例而已，并不用于限制本发明，对于本领域的技术人员来说，本发明可以有各种更改和变化。凡在本发明的精神和原则之内，所作的任何修改、等同替换、改进等，均应包含在本发明的保护范围之内。

Claims (10)

  1. 一种基于分段控制原理的高柔性桌式包边机，其特征在于，包括底座(5)、胎模安装座(4)、顶升机构(3)、所述胎模安装座(4)上设置的胎模(2)、位于所述胎模(2)四周的若干压刀机构(1)、位于所述胎模(2)上侧的压模机构(6)、以及驱动压模机构(6)转动的翻转机构(7)；
    其中，所述顶升机构(3)用于带动所述胎模(2)及门盖件上下移动，所述压刀机构(1)驱动压刀水平运动对所述门盖件进行包边；而若干组所述压刀机构(1)能拼接成汽车门盖件轮廓形状，用于汽车门盖件的包边。
  2. 根据权利要求1所述的基于分段控制原理的高柔性桌式包边机，其特征在于，所述压刀机构(1)包括底板(12)、压刀基座(11)、直线驱动单元(16)、以及设置在所述压刀基座(11)侧边上层的预包边压刀(8)和下层的终包边压刀(9)。
  3. 根据权利要求2所述的基于分段控制原理的高柔性桌式包边机，其特征在于，所述预包边压刀(8)和所述终包边压刀(9)都由若干段压刀刀片(41)拼接而成。
  4. 根据权利要求2所述的基于分段控制原理的高柔性桌式包边机，其特征在于，所述压刀机构(1)还包括自锁机构(15)，用于限制所述底板(12)移动。
  5. 根据权利要求1所述的基于分段控制原理的高柔性桌式包边机，其特征在于，所述顶升机构(3)包括驱动基座(22)、伺服电机(29)、滚珠丝杠(24)、顶升块(23)、以及对称设置的左楔形块(25)和右楔形块(26)。
  6. 根据权利要求5所述的基于分段控制原理的高柔性桌式包边机，其特征在于，所述左楔形块(25)和所述右楔形块(26)上分别设有滚轮(30)，所述顶升块(23)具有分别与所述左楔形块(25)和所述右楔形块(26)相配合的底部斜面，所述底部斜面包括两端的预包边面(231)、终包边面(233)、以及中间的快速行程面(232)，所述快速行程面(232)的倾斜角度大于所述预包边面(231)和所述终包边面(233)的倾斜角度；
    所述顶升块(23)的底部斜面前侧设有导轨板(27)，所述导轨板(27)为三段式导轨；所述三段式导轨包括预包边导轨(271)、快速行程导轨(272)以及终包边导轨(273)，且所述的预包边导轨(271)、终包边导轨(273)的倾斜角度分别与所述的预包边面(231)、终包边面(233)的倾斜角度对应相同。
  7. 根据权利要求1所述的基于分段控制原理的高柔性桌式包边机，其特征在于，所述压模机构(6)包括上压模(36)、上模驱动气缸(34)和导向杆(35)。
  8. 根据权利要求7所述的基于分段控制原理的高柔性桌式包边机，其特征在于，所述上压模(36)能分成若干个分区，每个分区设置一个夹紧块(361)，分区后的 若干所述夹紧块(361)沿门盖件的边环形设置在所述上压模(36)底部，并通过夹紧气缸(39)分别驱动，且所述夹紧块(361)与所述夹紧气缸(39)之间设有压力传感器(40)。
  9. 根据权利要求7所述的基于分段控制原理的高柔性桌式包边机，其特征在于，所述上模驱动气缸(34)配有泄压阀和比例阀。
  10. 一种基于分段控制原理的高柔性包边方法，其特征在于，包括如下步骤：
    S1、通过顶升机构(3)驱动胎模(2)至上件工位a，并将汽车门盖件放入胎模(2)，胎模(2)对汽车门盖件外板进行固定，压模机构(6)对汽车门盖件内板进行固定；
    S2、顶升机构(3)驱动胎模安装座(4)、胎模(2)、压模机构(6)、以及汽车门盖件同时移动至预包边等待工位c，使汽车门盖件四周的边位于预包边压刀(8)下侧；然后所有压刀机构(1)在直线驱动单元(16)驱动下向胎模(2)一侧移动，且所有预包边压刀(8)都被无缝拼接成汽车门盖件轮廓形状；
    S3、顶升机构(3)将胎模(2)向上顶升至预包边工位b，预包边压刀(8)将汽车门盖件外板的边折弯，完成预包边；顶升机构(3)驱动所述胎模(2)下降至预包边等待工位c，所述压刀机构(1)全部退回至等待工位；
    S4、顶升机构(3)驱动胎模(2)下降至终包边等待工位e,压刀机构(1)再次前推至工作位，终包边压刀(9)无缝拼接成整圈；
    S5、顶升机构(3)驱动胎模(2)顶升至终包边工位d，汽车门盖件四周的边在终包边压刀(9)的挤压下被压平；顶升机构(3)驱动胎模(2)退回到终包边等待工位e，压刀机构(1)再次退回至等待工位；
    S6、顶升机构(3)顶升胎模(2)回到上件工位a，同时压模机构(6)退回，最后取回包边后的汽车盖板，完成整个包边工序。
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