玉環(huan)雙山(shan)機械有限公司
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時間:2019-10-09 10:53:29??瀏(liu)覽次數:2423
從世界制造(zao)(zao)業和(he)鍛(duan)(duan)(duan)造(zao)(zao)工(gong)(gong)(gong)(gong)業的(de)(de)(de)發展趨勢(shi)來看,綠色制造(zao)(zao)和(he)生(sheng)(sheng)產(chan)(chan)(chan)過(guo)(guo)程(cheng)(cheng)(cheng)自動(dong)(dong)化(hua)是必然(ran)趨勢(shi)。現有鍛(duan)(duan)(duan)件(jian)(jian)(jian)制造(zao)(zao)企業需(xu)要(yao)提(ti)高生(sheng)(sheng)產(chan)(chan)(chan)過(guo)(guo)程(cheng)(cheng)(cheng)自動(dong)(dong)化(hua)程(cheng)(cheng)(cheng)度,減(jian)少生(sheng)(sheng)產(chan)(chan)(chan)過(guo)(guo)程(cheng)(cheng)(cheng)對工(gong)(gong)(gong)(gong)人(ren)的(de)(de)(de)健康危害,提(ti)高生(sheng)(sheng)產(chan)(chan)(chan)效率和(he)產(chan)(chan)(chan)品質量。我國(guo)(guo)(guo)雖然(ran)是一個(ge)鍛(duan)(duan)(duan)造(zao)(zao)大(da)國(guo)(guo)(guo),但不是一個(ge)鍛(duan)(duan)(duan)造(zao)(zao)強(qiang)國(guo)(guo)(guo),鍛(duan)(duan)(duan)造(zao)(zao)設備(bei)的(de)(de)(de)機(ji)械化(hua)和(he)自動(dong)(dong)化(hua)程(cheng)(cheng)(cheng)度也(ye)很低(di),大(da)多數鍛(duan)(duan)(duan)造(zao)(zao)設備(bei)處于手(shou)工(gong)(gong)(gong)(gong)運輸(shu)或半(ban)手(shou)工(gong)(gong)(gong)(gong)喂(wei)料落后的(de)(de)(de)狀態。在生(sheng)(sheng)產(chan)(chan)(chan)過(guo)(guo)程(cheng)(cheng)(cheng)中(zhong),燒(shao)到1000℃以上的(de)(de)(de)毛坯一般由鉗(qian)子工(gong)(gong)(gong)(gong)人(ren)夾(jia)緊在鍛(duan)(duan)(duan)造(zao)(zao)設備(bei)上,在鍛(duan)(duan)(duan)造(zao)(zao)過(guo)(guo)程(cheng)(cheng)(cheng)中(zhong)用(yong)鉗(qian)子翻轉工(gong)(gong)(gong)(gong)件(jian)(jian)(jian),然(ran)后用(yong)手(shou)動(dong)(dong)鉗(qian)子取出工(gong)(gong)(gong)(gong)件(jian)(jian)(jian),在加工(gong)(gong)(gong)(gong)過(guo)(guo)程(cheng)(cheng)(cheng)中(zhong)反復夾(jia)緊鋼鐵工(gong)(gong)(gong)(gong)件(jian)(jian)(jian),勞(lao)動(dong)(dong)強(qiang)度高。高溫高壓設備(bei)在任何時候都對操作(zuo)人(ren)員構(gou)成(cheng)嚴(yan)重的(de)(de)(de)安全威(wei)脅(xie)。在國(guo)(guo)(guo)外,已經(jing)有很多類(lei)似的(de)(de)(de)自動(dong)(dong)加工(gong)(gong)(gong)(gong)設備(bei),如日本(ben)、美國(guo)(guo)(guo)、德(de)國(guo)(guo)(guo)等(deng)類(lei)似的(de)(de)(de)機(ji)器人(ren)系統,各種生(sheng)(sheng)產(chan)(chan)(chan)線(xian)上的(de)(de)(de)機(ji)器人(ren)一直在鍛(duan)(duan)(duan)壓生(sheng)(sheng)產(chan)(chan)(chan)線(xian)上工(gong)(gong)(gong)(gong)作(zuo)很長時間。
目(mu)前(qian),用(yong)于鍛(duan)造生(sheng)產(chan)的(de)(de)工業機械(xie)手(shou)(shou)(shou)大多(duo)屬于第一代,主要(yao)依靠(kao)工人進(jin)行控(kong)制,改進(jin)方向主要(yao)是降低成本,提高精度。隨(sui)著自動化的(de)(de)發(fa)展(zhan),機械(xie)手(shou)(shou)(shou)的(de)(de)應用(yong)將越(yue)來越(yue)普遍。現(xian)有的(de)(de)鍛(duan)壓機械(xie)手(shou)(shou)(shou)系(xi)統一般與鍛(duan)壓機相結合,結構靈活性差(cha)。我國(guo)生(sheng)產(chan)的(de)(de)機械(xie)手(shou)(shou)(shou)系(xi)統價格在五六(liu)十萬元,國(guo)外生(sheng)產(chan)的(de)(de)機械(xie)手(shou)(shou)(shou)系(xi)統價格更(geng)高。無(wu)論是由(you)國(guo)內外企(qi)業生(sheng)產(chan)的(de)(de)鍛(duan)壓機械(xie)手(shou)(shou)(shou)系(xi)統,成本都很高,一般企(qi)業都難以承擔,因此開發(fa)一種(zhong)新型的(de)(de)機械(xie)手(shou)(shou)(shou),實現(xian)低投入下的(de)(de)鍛(duan)壓自動給料具有十分重要(yao)的(de)(de)意義。
鍛壓機械手是面向鍛壓自動化生(sheng)產而開發的工業自動化裝置,是一(yi)項復雜的機電一(yi)體化工程項目。研究開發內容包括(kuo):
(1)鍛壓機械手本(ben)體研(yan)究開發
機(ji)械(xie)(xie)手(shou)(shou)本體(ti)是系統(tong)(tong)的(de)任務執行單(dan)元,也是系統(tong)(tong)的(de)核(he)心。根據(ju)對鍛(duan)壓過程(cheng)中人工操作的(de)動作流程(cheng)分析(xi),確定(ding)鍛(duan)壓機(ji)械(xie)(xie)手(shou)(shou)需(xu)要(yao)的(de)動作方(fang)式(shi)及自由(you)度數目,設計出(chu)鍛(duan)壓機(ji)械(xie)(xie)手(shou)(shou)的(de)結構形式(shi)。根據(ju)特(te)定(ding)的(de)已有鍛(duan)壓設備,確定(ding)各軸需(xu)要(yao)的(de)運動范圍,進行實際的(de)范圍簡(jian)化(hua),在此基礎上(shang),進行機(ji)械(xie)(xie)手(shou)(shou)模型樣機(ji)的(de)整體(ti)機(ji)構設計。
(2)機械(xie)手控制系統開(kai)發
以工業PC機(ji)為平臺,以現代運(yun)動(dong)控制(zhi)技術為核心,開(kai)發一套控制(zhi)系統。通過運(yun)動(dong)控制(zhi)器動(dong)態控制(zhi)各執行(xing)元件,從而控制(zhi)機(ji)械(xie)手(shou)按運(yun)動(dong)的軌跡運(yun)動(dong)。
(3)機(ji)械(xie)手控(kong)制軟(ruan)件開(kai)發
設計(ji)一套界面友好、交(jiao)互性強的鍛壓機械(xie)手(shou)控制軟(ruan)件(jian)(jian),軟(ruan)件(jian)(jian)以Windos操作(zuo)系統(tong)為平臺(tai),便(bian)于人(ren)機交(jiao)互。通過軟(ruan)件(jian)(jian),完成機械(xie)手(shou)運動軌跡規劃(hua),控制機械(xie)手(shou)按(an)照一定路徑完成操作(zuo)任(ren)務(wu)。
(4)研(yan)究試驗(yan)方法(fa)及技術路線
鍛(duan)壓生產中(zhong)機械手應用的(de)解決方案(an)如圖1所示。
圖(tu)1 機械手(shou)研制具體(ti)實(shi)施方案(an)
對特(te)定(ding)(ding)工件(jian)的(de)鍛壓過程進行分析,確定(ding)(ding)采用圖2所示的(de)機(ji)械(xie)手為鍛壓機(ji)械(xie)手基本(ben)結構(gou)形(xing)式,根(gen)據特(te)定(ding)(ding)鍛壓設(she)備的(de)外(wai)形(xing)尺(chi)寸(cun)、操作尺(chi)寸(cun)、工件(jian)負(fu)載進行機(ji)械(xie)手模型(xing)樣(yang)機(ji)具體外(wai)形(xing)尺(chi)寸(cun)及詳細結構(gou)設(she)計。合(he)理劃分鍛壓過程動作及流(liu)程,設(she)置一些關鍵(jian)工藝參數,從而保證系(xi)統的(de)柔性。
圖2 機械手本體結構
機械手各運動軸實現(xian)精度如表1所示。
表1 機械手(shou)樣機本體各軸運動精(jing)度
鍛(duan)壓(ya)機(ji)械手(shou)(shou)(shou)通過(guo)手(shou)(shou)(shou)爪(zhua)(zhua)(zhua)開(kai)合機(ji)構(gou)(gou)拉動(dong)(dong)手(shou)(shou)(shou)爪(zhua)(zhua)(zhua)機(ji)構(gou)(gou),使手(shou)(shou)(shou)爪(zhua)(zhua)(zhua)能(neng)夠開(kai)合自如(ru),同時手(shou)(shou)(shou)爪(zhua)(zhua)(zhua)端部為V型槽(cao)結構(gou)(gou),可使抓取(qu)的(de)工(gong)(gong)件(jian)自動(dong)(dong)定心;手(shou)(shou)(shou)爪(zhua)(zhua)(zhua)轉(zhuan)動(dong)(dong)機(ji)構(gou)(gou)可帶著手(shou)(shou)(shou)爪(zhua)(zhua)(zhua)和(he)手(shou)(shou)(shou)爪(zhua)(zhua)(zhua)伸縮機(ji)構(gou)(gou)進行90°轉(zhuan)動(dong)(dong),從而使工(gong)(gong)件(jian)能(neng)在鍛(duan)壓(ya)的(de)過(guo)程中實(shi)現翻轉(zhuan);手(shou)(shou)(shou)爪(zhua)(zhua)(zhua)伸縮機(ji)構(gou)(gou)可使手(shou)(shou)(shou)爪(zhua)(zhua)(zhua)順利(li)達到抓取(qu)位置(zhi)抓取(qu)工(gong)(gong)件(jian),并能(neng)順利(li)地將工(gong)(gong)件(jian)放在鍛(duan)模上;手(shou)(shou)(shou)爪(zhua)(zhua)(zhua)升降機(ji)構(gou)(gou)能(neng)保證(zheng)手(shou)(shou)(shou)爪(zhua)(zhua)(zhua)將工(gong)(gong)件(jian)從放置(zhi)位置(zhi)拿(na)起,并在鍛(duan)壓(ya)位置(zhi)放下,在工(gong)(gong)件(jian)的(de)搬運過(guo)程中防止(zhi)與其他機(ji)構(gou)(gou)相(xiang)碰;控制系(xi)統采用電氣(qi)伺服與氣(qi)動(dong)(dong)驅(qu)動(dong)(dong)的(de)混(hun)合驅(qu)動(dong)(dong)方式(shi),具(ju)有質量輕(qing)、響應(ying)快的(de)特點。
物料傳感器檢測到鍛(duan)(duan)件;從(cong)初始位(wei)置(zhi)開(kai)始,垂直氣(qi)缸(gang)向(xiang)上動(dong)(dong)作到頂(ding)端,上位(wei)磁(ci)性開(kai)關(guan)接(jie)通,電(dian)(dian)(dian)磁(ci)閥恢(hui)復(fu)中位(wei);橫向(xiang)移動(dong)(dong)機(ji)構啟動(dong)(dong),向(xiang)右運(yun)動(dong)(dong),到右端限位(wei)光(guang)電(dian)(dian)(dian)開(kai)關(guan)變(bian)化,控制橫向(xiang)移動(dong)(dong)的伺服電(dian)(dian)(dian)機(ji)停止;水(shui)平氣(qi)缸(gang)收縮,后端磁(ci)性開(kai)關(guan)接(jie)通,電(dian)(dian)(dian)磁(ci)閥保持線圈通電(dian)(dian)(dian)狀態;垂直氣(qi)缸(gang)向(xiang)下運(yun)動(dong)(dong)到中位(wei)磁(ci)性開(kai)關(guan)接(jie)通,電(dian)(dian)(dian)磁(ci)閥恢(hui)復(fu)中位(wei);電(dian)(dian)(dian)磁(ci)閥線圈斷(duan)電(dian)(dian)(dian)狀態,水(shui)平氣(qi)缸(gang)推出,前端磁(ci)性開(kai)關(guan)接(jie)通,物品爪夾(jia)住鍛(duan)(duan)件。
物料傳(chuan)感器檢測空氣錘(chui)(chui)頭,錘(chui)(chui)頭抬起,傳(chuan)感器接收到(dao)信號,鍛(duan)(duan)(duan)(duan)(duan)件(jian)(jian)(jian)才能被挪動(dong)(dong)和轉動(dong)(dong);踏板電(dian)(dian)機(ji)啟動(dong)(dong),上限位(wei)光電(dian)(dian)開(kai)(kai)關(guan)變化(hua),向下(xia)運(yun)(yun)動(dong)(dong)到(dao)控(kong)制鍛(duan)(duan)(duan)(duan)(duan)錘(chui)(chui)輕打(da)(da)位(wei)置(zhi);鍛(duan)(duan)(duan)(duan)(duan)錘(chui)(chui)落(luo)下(xia),抬起 (周期3次(ci)/s),一(yi)次(ci)0.43 s;鍛(duan)(duan)(duan)(duan)(duan)件(jian)(jian)(jian)旋轉電(dian)(dian)機(ji)從(cong)鍛(duan)(duan)(duan)(duan)(duan)錘(chui)(chui)開(kai)(kai)始下(xia)落(luo)的(de)0.19 s(鍛(duan)(duan)(duan)(duan)(duan)打(da)(da)一(yi)刻(ke)的(de)0.017 s后(hou))開(kai)(kai)始旋轉90°,零位(wei)光電(dian)(dian)開(kai)(kai)關(guan)變化(hua),經歷時間0.33 s;鍛(duan)(duan)(duan)(duan)(duan)錘(chui)(chui)第(di)二(er)次(ci)鍛(duan)(duan)(duan)(duan)(duan)打(da)(da),后(hou)旋轉鍛(duan)(duan)(duan)(duan)(duan)件(jian)(jian)(jian)45°;之后(hou)重(zhong)(zhong)復前(qian)3步的(de)過程若干(gan)次(ci),直至(zhi)(zhi)預計直徑(jing)變為44 mm;踏板電(dian)(dian)機(ji)啟動(dong)(dong),向下(xia)運(yun)(yun)動(dong)(dong)到(dao)控(kong)制鍛(duan)(duan)(duan)(duan)(duan)錘(chui)(chui)重(zhong)(zhong)打(da)(da)位(wei)置(zhi);重(zhong)(zhong)復鍛(duan)(duan)(duan)(duan)(duan)錘(chui)(chui)落(luo)下(xia),抬起;鍛(duan)(duan)(duan)(duan)(duan)件(jian)(jian)(jian)旋轉電(dian)(dian)機(ji),從(cong)鍛(duan)(duan)(duan)(duan)(duan)錘(chui)(chui)開(kai)(kai)始下(xia)落(luo)的(de)0.18 s(鍛(duan)(duan)(duan)(duan)(duan)打(da)(da)一(yi)刻(ke)的(de)0.017 s后(hou))開(kai)(kai)始旋轉90°經歷時間0.33 s;鍛(duan)(duan)(duan)(duan)(duan)錘(chui)(chui)第(di)二(er)次(ci)鍛(duan)(duan)(duan)(duan)(duan)打(da)(da),后(hou)旋轉鍛(duan)(duan)(duan)(duan)(duan)件(jian)(jian)(jian)45°;之后(hou)重(zhong)(zhong)復前(qian)兩步的(de)過程若干(gan)次(ci),直至(zhi)(zhi)垂(chui)直氣缸(gang)下(xia)位(wei)磁性開(kai)(kai)關(guan)接通,預計直徑(jing)變為37 mm;踏板電(dian)(dian)機(ji)啟動(dong)(dong),向上運(yun)(yun)動(dong)(dong)到(dao)控(kong)制鍛(duan)(duan)(duan)(duan)(duan)錘(chui)(chui)懸空位(wei)置(zhi)。
垂直氣(qi)(qi)缸向(xiang)(xiang)上(shang)動(dong)(dong)作,到(dao)頂端,上(shang)位(wei)(wei)(wei)(wei)磁(ci)(ci)性開(kai)關(guan)(guan)(guan)接通,電(dian)(dian)(dian)(dian)(dian)(dian)磁(ci)(ci)閥(fa)(fa)恢(hui)復中位(wei)(wei)(wei)(wei);橫向(xiang)(xiang)移(yi)動(dong)(dong)機(ji)(ji)構啟動(dong)(dong),向(xiang)(xiang)左運動(dong)(dong),左端限位(wei)(wei)(wei)(wei)光電(dian)(dian)(dian)(dian)(dian)(dian)開(kai)關(guan)(guan)(guan)變化(hua)(hua),控制(zhi)橫向(xiang)(xiang)移(yi)動(dong)(dong)的伺(si)服(fu)電(dian)(dian)(dian)(dian)(dian)(dian)機(ji)(ji)停(ting)止(zhi);垂直氣(qi)(qi)缸向(xiang)(xiang)下(xia)運動(dong)(dong)到(dao)中位(wei)(wei)(wei)(wei)磁(ci)(ci)性開(kai)關(guan)(guan)(guan)接通,電(dian)(dian)(dian)(dian)(dian)(dian)磁(ci)(ci)閥(fa)(fa)恢(hui)復中位(wei)(wei)(wei)(wei);鍛(duan)件旋(xuan)(xuan)(xuan)轉(zhuan)電(dian)(dian)(dian)(dian)(dian)(dian)機(ji)(ji)旋(xuan)(xuan)(xuan)轉(zhuan),零(ling)(ling)位(wei)(wei)(wei)(wei)光電(dian)(dian)(dian)(dian)(dian)(dian)開(kai)關(guan)(guan)(guan)變化(hua)(hua),鍛(duan)件旋(xuan)(xuan)(xuan)轉(zhuan)電(dian)(dian)(dian)(dian)(dian)(dian)機(ji)(ji)停(ting)止(zhi);水平氣(qi)(qi)缸收(shou)縮,后(hou)端磁(ci)(ci)性開(kai)關(guan)(guan)(guan)接通,電(dian)(dian)(dian)(dian)(dian)(dian)磁(ci)(ci)閥(fa)(fa)保持(chi)(chi)線圈通電(dian)(dian)(dian)(dian)(dian)(dian)狀態(tai),物品爪張(zhang)開(kai),鍛(duan)件掉落(luo)(luo);垂直氣(qi)(qi)缸向(xiang)(xiang)上(shang)動(dong)(dong)作到(dao)頂端,上(shang)位(wei)(wei)(wei)(wei)磁(ci)(ci)性開(kai)關(guan)(guan)(guan)接通,電(dian)(dian)(dian)(dian)(dian)(dian)磁(ci)(ci)閥(fa)(fa)恢(hui)復中位(wei)(wei)(wei)(wei);橫向(xiang)(xiang)移(yi)動(dong)(dong)機(ji)(ji)構啟動(dong)(dong),右端限位(wei)(wei)(wei)(wei)光電(dian)(dian)(dian)(dian)(dian)(dian)開(kai)關(guan)(guan)(guan)變化(hua)(hua),向(xiang)(xiang)左運動(dong)(dong)到(dao)鍛(duan)位(wei)(wei)(wei)(wei)一,控制(zhi)橫向(xiang)(xiang)移(yi)動(dong)(dong)的伺(si)服(fu)電(dian)(dian)(dian)(dian)(dian)(dian)機(ji)(ji)停(ting)止(zhi);垂直氣(qi)(qi)缸向(xiang)(xiang)下(xia)運動(dong)(dong)到(dao)中位(wei)(wei)(wei)(wei)磁(ci)(ci)性開(kai)關(guan)(guan)(guan)接通,電(dian)(dian)(dian)(dian)(dian)(dian)磁(ci)(ci)閥(fa)(fa)恢(hui)復中位(wei)(wei)(wei)(wei);鍛(duan)件旋(xuan)(xuan)(xuan)轉(zhuan)電(dian)(dian)(dian)(dian)(dian)(dian)機(ji)(ji)旋(xuan)(xuan)(xuan)轉(zhuan),零(ling)(ling)位(wei)(wei)(wei)(wei)光電(dian)(dian)(dian)(dian)(dian)(dian)開(kai)關(guan)(guan)(guan)變化(hua)(hua),鍛(duan)件旋(xuan)(xuan)(xuan)轉(zhuan)電(dian)(dian)(dian)(dian)(dian)(dian)機(ji)(ji)停(ting)止(zhi);水平氣(qi)(qi)缸收(shou)縮,后(hou)端磁(ci)(ci)性開(kai)關(guan)(guan)(guan)接通,電(dian)(dian)(dian)(dian)(dian)(dian)磁(ci)(ci)閥(fa)(fa)保持(chi)(chi)線圈通電(dian)(dian)(dian)(dian)(dian)(dian)狀態(tai),物品爪張(zhang)開(kai),鍛(duan)件掉落(luo)(luo)。如圖(tu)3為鍛(duan)件旋(xuan)(xuan)(xuan)轉(zhuan)電(dian)(dian)(dian)(dian)(dian)(dian)機(ji)(ji)進給(gei)圖(tu),圖(tu)4為步進電(dian)(dian)(dian)(dian)(dian)(dian)機(ji)(ji)進給(gei)圖(tu)。
圖3 鍛件旋(xuan)轉電機(ji)進給圖
圖4 鍛件步進電機進給圖
隨著工(gong)業(ye)自動(dong)化的(de)(de)(de)發展(zhan)(zhan),機械(xie)手(shou)(shou)逐漸成(cheng)(cheng)為一門新興(xing)的(de)(de)(de)學科,并得到了(le)迅速的(de)(de)(de)發展(zhan)(zhan)。機械(xie)手(shou)(shou)廣(guang)(guang)泛應用于鍛(duan)造(zao)、沖(chong)壓、鑄造(zao)、焊接、裝配(pei)、加工(gong)、油漆(qi)、熱處理等行(xing)業(ye)。特(te)別(bie)是在惡劣(lie)的(de)(de)(de)工(gong)作環境中(zhong),如體積(ji)大、溫度高、有毒、危險、放射性、多粉塵等,機械(xie)手(shou)(shou)因(yin)其顯(xian)著的(de)(de)(de)優點(dian)而受到人(ren)們的(de)(de)(de)特(te)別(bie)關(guan)注。該項目的(de)(de)(de)成(cheng)(cheng)功(gong)研究為后續(xu)的(de)(de)(de)深入研究和推廣(guang)(guang)奠定了(le)堅(jian)實(shi)的(de)(de)(de)基礎。只要(yao)對(dui)現有鍛(duan)造(zao)設備鍛(duan)造(zao)動(dong)作與機械(xie)手(shou)(shou)動(dong)作協(xie)調研究,投(tou)資二十(shi)多萬元即可(ke)實(shi)現自動(dong)鍛(duan)造(zao)。同時,也可(ke)以在極端的(de)(de)(de)制(zhi)造(zao)環境中(zhong)推廣(guang)(guang)應用,促進相(xiang)關(guan)產業(ye)的(de)(de)(de)綠色可(ke)持續(xu)發展(zhan)(zhan)。