During shaft alignment, after the workpiece is clamped by the center of the driving and driven rotation centers, the center is driven by the speed regulating motor and transmitted to the center of the driven rotation center through the workpiece. At the same time, the measuring device connected with the movable support detects the total jitter (TIR) of the workpiece surface, the photoelectric encoder in the driven rotation center measures the direction of the total jitter of the workpiece surface, and the computer judges the maximum bending position and direction of the workpiece according to these data. When the maximum bending point of the workpiece is upward, the command to stop the rotation of the workpiece is issued, and the correction amount is calculated according to the TIR amplitude and the set parameters, so as to realize the accurate correction of the workpiece, the clamping and loosening of the workpiece, the selection of the movable support position, the movement of the workpiece table, and the fast and slow feed of the punch are managed by PLC.
(1) bearing frame
JE series automatic shaft straightener can be divided into C type and portal type according to the main machine structure. The main machine of C-type straightener adopts open frame structure, with simple structure, small floor space (electric control cabinet installed in the main machine), good adaptability to ultra-long (≥900mm) workpieces, and great advantages in large tonnage products. The main engine of the door straightener adopts a closed frame structure, which has the characteristics of symmetrical appearance, compact structure, good rigidity of the main engine, fast moving speed of the oil cylinder, high straightening efficiency, small moving inertia of the oil cylinder, small positioning error and easy installation on the auto production line. This structure is generally used for straightening short workpieces and levelers with small tonnage, and automatic straightening can be realized by selecting automatic loading and unloading mechanism.
These two models are impartial in use and can be chosen by any industry. The difference lies in the requirements of actual work. For example, C-type machine can be selected for large design tonnage, and C-type machine can be selected for long workpieces. But if the straightening efficiency is high and the workpiece is not very long, you can choose a gantry machine. In terms of working mode, the C-type straightener adopts the pressure head mechanism to fix the position, and the motor drives the rack and pinion mechanism to control the moving table to switch the axial straightening point of the workpiece. According to the invention, the axial straightening point of the workpiece is switched by controlling the moving ram mechanism through the fixed workbench and the motor-driven ball screw pair. The pressure head moves quickly and the inertia of the system is small. When switching the axial straightening point of workpiece, the positioning of portal straightener is better than that of C-type straightener. When there is enough space around the straightening point, there is little difference between the two models.
The positioning and clamping parts on the worktable of C-type straightener and gantry straightener are all designed as building blocks, so as to adapt to the installation and adjustment of various movable supports, measuring units, friction drive devices and top-type rotary centers, and at the same time facilitate the maintenance and replacement of vulnerable parts, which is more conducive to users to switch and expand the straightening process of new product parts.
The key components of the mechanical system are the products of world-famous companies, such as THK, Dongfang, Nissin and Rohm. And the operation accuracy of the straightener is maintained for a long time.
(2) Hydraulic control system
Pump station, hydraulic valve group, actuating cylinder and hydraulic control loop constitute the hydraulic system of the leveler. The key components of the hydraulic system are products of world-renowned companies such as Japanese Oil Research Institute, Italian ATOS and Taiwan Province Northman, which ensure the accuracy, stability and reliability of the hydraulic system. When the straightener is on standby, the unique energy-saving unloading design is more suitable for the vast regional climate differences in China, which ensures that the automatic straightener can run continuously at a suitable working temperature in any region.
(3) Pneumatic control unit
The pneumatic control loop consisting of pneumatic triplet, pressure relay, container valve group and actuating cylinder constitutes the pneumatic unit of the straightener. The pneumatic unit mainly controls and executes actions such as clamping, positioning, sorting and conveying of workpieces, and each executing cylinder is equipped with a position detection switch to feed back the execution of actions to the system, which is convenient for the control of action flow and the diagnosis and investigation of faults. The pneumatic components are mainly made of world-renowned companies such as Japanese SMC, German FESTO, and Taiwan Province SHAKO, with sensitive and reliable actions and long service life.
(4), the workpiece radial runout detection unit
A mechanical lever measuring amplification mechanism, a high-precision displacement and angle sensor, a precision speed regulating motor and a measuring probe constitute a workpiece radial runout detection unit. The probe can be used to accurately measure the pure circular cross section, D-shaped cross section and radial runout of indexing circle of gears or splines of shaft workpieces, and there are various measuring methods, such as ultra-hard round rod measuring tappets, fully open or semi-open containing measuring sheets, high-precision standard gears and so on. The complicated and meticulous design ensures the accuracy and practicability of the measurement.
(5) Programmable Control Center (PLC)
Programmable control center is the key component of straightener. The complicated and orderly actions of the straightener are all carried out under the control of its program. PLC and computer processing system communicate with each other, and coordinate and control each executive component to perform actions such as clamping, measuring, straightening and positioning, pressurizing and implementing correction in an orderly manner. The system adopts Japanese Omron series programmable controllers (products of Japanese Mitsubishi and German Siemens can also be selected according to users' requirements), and the electrical operation and execution components mainly adopt products of Japanese Mitsubishi, Fuji, Omron, Panasonic and French Schneider, which are stable and reliable.
(6), computer processing system
Ultra-high-precision data acquisition system, safe and reliable input and output system, industrial comprehensive workstation with large-screen color LCD display, high-professional software package, Chinese man-machine interaction interface, color graphic display and printable data statistical output constitute the computer processing system of the straightener.
In the aspect of software design, based on the advanced experience of foreign professional manufacturers, we added our unique straightening concept, in which point vibration correction greatly accelerated the straightening speed. Vector decomposition correction is specially developed and designed for workpieces with D-shaped cross section or local surface hardening (such as steering gear rack). This kind of workpiece usually has different mechanical properties in different directions because of irregular shape or uneven heat treatment in all directions. It is difficult to meet the technical requirements of the product if the traditional correction method is adopted. Vector decomposition correction can establish different correction models in different directions for correction, which solves the problem that this kind of workpiece is difficult to straighten.
In software implementation, we use C++ BUILDER 6.0 to program, and the outstanding performance of C language application in industrial control field makes our software package perform well in code execution speed and stability. Chinese human-computer interaction interface is more in line with the usage habits of Chinese people, and it is easier for operators to understand and master. Detailed online electronic graphic help system can help beginners to quickly master the operation essentials. The storage of workpiece parameters can be expanded at will, which meets the requirement of multi-purpose of one machine. Perfect fault self-diagnosis system enables operators to quickly check equipment faults. The measurement dynamic waveform display can find out the defects such as roundness error, burr and pit on the surface of the workpiece very intuitively. The most commendable thing is that we have the ability to redevelop the whole system and technical team, and even carry out special design for special workpieces and reasonable requirements put forward by users to realize technical interaction with users, so as to give full play to the functions and efficiency of the equipment.
Domestic development history