Multi-station automatic gear machining equipment and machining method thereof

Abstract

The invention discloses multi-station automatic gear machining equipment and a method thereof, and aims to solve the problems of low efficiency, unstable quality and high collision rejection rate caused by the fact that multiple procedures depend on manual operation in the pre-welding preparation process of a new energy gear welding assembly. The equipment comprises a supporting frame, and a gear demagnetizing device, a gear feeding device, a power frequency heating device, a gear press-fitting device, a gear transferring truss, a control electric cabinet, a residual magnetism detection device, an unqualified product discharging line and a pre-welding heating device which are arranged on the supporting frame. All the devices are connected through a gear transfer truss and are controlled by a control electric cabinet in a centralized mode, and the processes of demagnetization, preheating before press fitting, press fitting, residual magnetism detection and preheating before welding are sequentially completed. Through high integration and full-process automation, the number of operators is reduced to one, the production efficiency and the product quality stability are greatly improved, and the gear assembly production line is suitable for large-scale automatic production of gear assemblies.

Description

Technical Field

[0001] This application belongs to the technical field of gear processing equipment, and specifically relates to a multi-station automated gear processing equipment and its processing method. Background Technology

[0002] In the processing of welding components for new energy gears, traditional methods typically employ multiple independent machines to complete steps such as demagnetizing individual parts, preheating before press-fitting, press-fitting, residual magnetism detection, and preheating before welding. These steps rely heavily on manual labor, which not only demands high levels of professional skill from operators but also makes parts susceptible to damage and scrap due to human error, severely impacting production efficiency and product quality.

[0003] Especially in the preheating stage before pressing, existing technologies mostly use ordinary induction heating devices to heat the gear on one side or in a localized area, with a heating time of 2-3 minutes. The temperature distribution is uneven, which can easily cause excessive temperature difference between the inner and outer rings of the gear, affecting the pressing pass rate. In the residual magnetism detection stage, handheld gaussmeters are usually used for manual measurement, which has problems such as large operating errors, easy wear of the probe, and low detection efficiency.

[0004] In addition, the lack of effective connection between the various processes in the existing production line makes it impossible to achieve continuous automated operation, resulting in a long overall processing cycle, high labor intensity, and poor quality consistency, which makes it difficult to meet the production needs of large-scale and high-precision new energy gear components. Summary of the Invention

[0005] The purpose of this application is to provide a multi-station automated gear processing equipment and method. This addresses the problems of low efficiency, unstable quality, and high scrap rate due to reliance on manual operation during the pre-welding preparation of new energy gear welding components, as mentioned in the background art.

[0006] To achieve the above objectives, this application adopts the following technical solution: In a first aspect, a multi-station automated gear processing equipment is provided, including a support frame, and a gear demagnetizing device, a gear feeding device, an industrial frequency heating device, a gear pressing device, a gear transfer truss, a control cabinet, a residual magnetism detection device, a defective discharge line, and a pre-welding heating device disposed on the support frame. The discharge end of the gear demagnetizing device is connected to the infeed end of the gear feeding device; The gear feeding device is configured to transfer the demagnetized disc gear to the power frequency heating device and the demagnetized shaft gear to the gear pressing device; The discharge end of the power frequency heating device is connected to the feed end of the gear plate of the gear pressing device through the gear transfer truss. The discharge end of the gear pressing device is connected to the inlet end of the residual magnetism detection device through the gear transfer truss. The defective product outlet of the residual magnetism detection device is connected to the defective product discharge line, and the qualified product outlet is connected to the feed end of the pre-welding heating device. The control cabinet is connected to each device via signal and is used to control each device to operate in coordination according to the processing sequence.

[0007] In one possible implementation, the power frequency heating device includes a power frequency heating platform, a heating assembly, an upper heating induction head, an induction head lifting mechanism, and a material unloading robot assembly; The power frequency heating platform is mounted on the support frame, and the power frequency heating device includes a power frequency heating platform, a heating component, a heating upper induction head, an induction head lifting mechanism, a material unloading robot component, and a temperature detection component. The heating component is fixedly mounted on the support frame. The power frequency heating platform and the induction head lifting mechanism are both connected to the heating component. The power frequency heating platform and the upper heating induction head are arranged vertically in correspondence to each other, forming an upper and lower induction heating structure. The upper heating sensor head is connected to the sensor head lifting mechanism, which drives the upper heating sensor head to rise and fall to form a heating gap of 2-3 cm with the surface of the gear placed on the power frequency heating table. The temperature detection component integrates an infrared temperature sensor, which is used to move horizontally above the gear and focus on detecting its surface temperature, and feeds the temperature signal back to the control cabinet. The unloading robot assembly serves as the discharge end of the power frequency heating device, used to grab the gear and transfer it to the gear transfer truss after the temperature detection meets the standard.

[0008] In one possible implementation, the gear demagnetizing device includes a demagnetizing device bracket, and a gear transport belt, a demagnetizer, a gear loading position, a detector, and a gear unloading position disposed on the demagnetizing device bracket; The demagnetizing device bracket is mounted on the support frame, the gear conveyor belt passes through the demagnetizer, and the two ends of the gear conveyor belt correspond to the gear loading position and the gear unloading position, respectively. The detector is set at the gear loading position to sense the part arrival signal and trigger the demagnetizing device to start.

[0009] In one possible implementation, the gear feeding device includes a sprocket feeding rotating assembly, a sprocket heating feeding assembly, a sprocket picking chuck, a shaft gear picking chuck, a shaft gear press-fit feeding assembly, and a gear conveyor belt disposed on the support frame. The gear feeding and rotating assembly is linked with the gear heating and feeding assembly to drive the gear picking claw to grab and transfer the gear to the gear conveyor belt, and then transfer it to the power frequency heating device via the gear conveyor belt. The shaft gear picking claw cooperates with the shaft gear pressing and feeding assembly to pick up and transfer the shaft gear to the gear pressing device.

[0010] In one possible implementation, the gear pressing device includes a shaft gear positioning assembly, a pressing electric cylinder, a drive motor, a plate gear positioning assembly, a pressing robot, and a shaft gear clamping chuck, all mounted on the support frame. The drive motor is connected to the press-fit electric cylinder, the press-fit electric cylinder is connected to the shaft gear positioning assembly, and the shaft gear clamping chuck is disposed on the shaft gear positioning assembly for clamping and positioning the shaft gear; The press-fit electric cylinder is used to drive the shaft gear positioning assembly to press the shaft gear into the disc gear positioned on the disc gear positioning assembly; The pressing robot arm is rotatably mounted and used to rest against the gear during the pressing process.

[0011] In one possible implementation, the gear transfer truss includes a first drive module, upper and lower parallel racks, truss support, assembly transport robot, assembly rotation assembly, limit mechanism one, limit mechanism two, second drive module and horizontal parallel rack, all mounted on the support frame. The first drive module is used to drive the truss support to move along the upper and lower parallel racks between the limiting mechanism one and the limiting mechanism two; The assembly rotation component is mounted on the assembly transport robot and is used to drive the assembly to rotate and adjust its posture. The second drive module is used to drive the assembly transport robot to move horizontally.

[0012] In one possible implementation, the residual magnetism detection device includes a detection platform, a sensor head support and an I-shaped slide rail, a rotary motor, a motion mechanism and a residual magnetism detection sensor head, all mounted on the support frame. The rotary motor is driven by the detection table and is used to drive the assembly to rotate; the I-shaped slide rail is fixedly installed, the induction head support is slidably connected to the I-shaped slide rail, and the residual magnetism detection induction head is installed on the induction head support; The motion mechanism is driven to move horizontally through the sensor head support to detect residual magnetism in the rotating assembly.

[0013] In one possible implementation, the defective discharge line includes a residual magnetism analysis element, a drive motor, a motion component, a robotic arm rotation mechanism, a residual magnetism detection unloading robotic arm, and a defective discharge belt, all mounted on the support frame. The drive motor is connected to the motion component, the motion component is connected to the robotic arm rotation mechanism, and the robotic arm rotation mechanism is connected to the residual magnetism detection and unloading robotic arm. It is used to grab unqualified parts according to the judgment result and output them through the unqualified discharge belt.

[0014] In one possible implementation, the pre-welding heating device includes a heating platform, a support base, a lifting cylinder, an upper heater, a tooling placement device, and a detector, all mounted on the support frame. The support base is fixed to the support frame, the lifting cylinder is installed on the support base, and the lifting cylinder is driven to connect to the upper heater for driving it to lift and lower relative to the assembly placed on the heating platform. The placement fixture is set corresponding to the heating platform and is used to support the preheated assembly. The detector corresponds to the placement fixture and is used to detect whether the assembled parts are in place and send a material picking command.

[0015] Secondly, a multi-station automated gear machining method is provided, which utilizes the multi-station automated gear machining equipment of the first aspect, and includes the following steps: S1: Demagnetization step: Demagnetize the gear assembly in the gear demagnetizing device; S2: Feeding and preheating steps: The demagnetized disc gears are transferred to the power frequency heating device for preheating through the gear feeding device, and the demagnetized shaft gears are transferred to the gear pressing device at the same time. S3: Pressing step: The preheated disc gear is transferred to the gear pressing device through the gear transfer gantry and pressed together with the shaft gear to form a composite part; S4: Inspection and sorting steps: The press-fitted assemblies are transferred to the residual magnetism detection device for inspection via the gear transfer gantry. Unqualified assemblies are output from the unqualified discharge line, and qualified assemblies are transferred to the pre-welding heating device. S5: Preheating step: Preheat qualified components in a preheating device in preparation for welding.

[0016] In one possible implementation, the gear demagnetizing device, gear feeding device, power frequency heating device, gear pressing device, gear transfer truss, residual magnetism detection device, unqualified discharge line, and pre-welding heating device are all electrically connected to the control cabinet.

[0017] Compared with the prior art, this application has the following beneficial effects: This application provides a multi-station automated gear processing equipment that achieves a leapfrog improvement in production efficiency and product quality through highly integrated and intelligent design. The core of this system lies in integrating multiple independent processes such as demagnetization, preheating, pressing, testing, and pre-welding preheating into a single machine, uniformly coordinated by a control cabinet. Precise material flow is achieved through a gear transfer gantry, constructing a complete automated production unit. This optimizes a production line that previously required multiple skilled workers to one that only needs monitoring, significantly reducing labor costs and intensity, and fundamentally eliminating the risk of parts being damaged or scrapped due to human error.

[0018] In one possible implementation, an innovative multi-directional three-dimensional heating structure allows heat to be simultaneously and evenly transferred to the upper and lower end faces and inner and outer ring areas of the gear. This successfully controls the overall heating time to within one minute, resulting in a significant improvement in production efficiency. Simultaneously, this technology ensures that the temperature difference between different parts of the gear is strictly controlled within a few degrees Celsius, fundamentally eliminating the risk of localized overheating. This significantly improves the first-pass yield of the pressing process, bringing product quality stability to a new level.

[0019] One possible implementation employs a fully automated inspection scheme. A rotary motor drives the parts to rotate at a uniform speed, while a sensor head performs non-contact scanning measurements. This design completely eliminates human error from affecting the inspection results, ensuring consistency and accuracy. The precise millimeter-level non-contact gap protects the precision probe, extending its lifespan several times over and effectively reducing long-term maintenance costs. This inspection method provides a reliable guarantee for strictly controlling demagnetization quality and significantly improving the subsequent welding pass rate, resulting in a systematic improvement in the overall product quality stability.

[0020] A multi-station automated gear machining method is disclosed. This method optimizes and solidifies the machining process, achieving standardization and efficiency in production. It strictly adheres to standardized procedures, utilizing automated equipment to execute each step. This method transforms complex, skill-dependent machining tasks into stable, repeatable standardized procedures. This not only significantly shortens the machining cycle of individual products but also ensures that each product is processed through a completely consistent process path and parameters. This results in uniform product quality and high predictability, providing a solid technical guarantee for large-scale, batch production. Attached Figure Description

[0021] Figure 1 A top view of a multi-station automated gear processing equipment provided in this application; Figure 2 This application provides an overall structural schematic diagram of a multi-station automated gear processing equipment; Figure 3This is a schematic diagram of the structure of a gear demagnetizing device provided in this application; Figure 4 This is a schematic diagram of the structure of a gear feeding device provided in this application; Figure 5 This application provides a schematic diagram of the structure of an industrial frequency heating device; Figure 6 This application provides a schematic diagram of the structure of a gear pressing device; Figure 7 This application provides a structural schematic diagram of a gear transfer truss. Figure 8 This application provides a schematic diagram of another state structure of a gear transfer truss; Figure 9 This is a schematic diagram of the structure of a residual magnetism detection device provided in this application; Figure 10 This application provides a structural schematic diagram of a substandard discharge line; Figure 11 This is a schematic diagram of a pre-welding heating device provided in this application.

[0022] Figure reference numerals: 01. Robot; 02. Support frame; 1. Gear demagnetizing device; 11. Demagnetizing device bracket; 13. First detector; 14. Gear conveyor belt; 15. Demagnetizer; 16. Gear picking position; 2. Gear feeding device; 21. Gear feeding rotating assembly; 22. Gear heating feeding assembly; 23. Gear picking chuck; 24. Shaft gear picking chuck; 25. Shaft gear pressing feeding assembly; 3. Industrial frequency heating device; 31. Industrial frequency heating table; 32. Heating assembly; 33. Heating upper induction head; 34. Induction head lifting mechanism; 35. Unloading robot assembly; 36. Upper induction assembly; 4. Gear pressing device; 41. Shaft gear positioning assembly; 411. Slide groove; 42. Pressing electric cylinder; 43. First drive motor; 44. Gear positioning assembly; 45. Pressing robot; 46. Shaft gear clamping chuck; 47. Support plate 5. Gear transfer truss; 51. First drive module; 52. Upper and lower parallel racks; 53. Truss support; 54. Assembly transport robot; 55. Assembly rotation assembly; 56. Limiting mechanism; 58. Second drive module; 59. Horizontal parallel rack; 6. Control cabinet; 7. Residual magnetism detection device; 71. Motion mechanism; 72. I-shaped slide rail; 73. Induction head support; 74. Residual magnetism detection induction head; 75. Detection table; 76. Rotary motor; 8. Non-conforming discharge line; 81. Residual magnetism analysis element; 82. Second drive motor; 83. Motion assembly; 84. Robot rotation mechanism; 85. Residual magnetism detection unloading robot; 86. Non-conforming discharge belt; 9. Pre-welding heating device; 91. Heating platform; 92. Heating support; 93. Lifting cylinder; 94. Upper heater; 95. Placement fixture; 96. Second detector. Detailed Implementation

[0023] In the following description, only certain exemplary embodiments are briefly described. As those skilled in the art will recognize, the described embodiments can be modified in various ways without departing from the spirit or scope. Therefore, the drawings and description are considered to be exemplary in nature and not restrictive.

[0024] In the description of this application, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential", etc., indicating the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application.

[0025] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this application, "a plurality of" means two or more, unless otherwise explicitly defined. The specific embodiments of this application will be further described in detail below with reference to the accompanying drawings.

[0026] In this application, unless otherwise expressly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection, an electrical connection, or a communication connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0027] In this application, unless otherwise expressly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature being directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature being directly above or diagonally above the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0028] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0029] like Figure 1 , Figure 2 and Figure 3 As shown, this application discloses a multi-station automated gear processing equipment, the core of which is to achieve the integrated installation of various functional devices through the support frame 02, forming a fully automated processing line.

[0030] The multi-station automated gear processing equipment includes a support frame 02, and gear demagnetizing device 1, gear feeding device 2, power frequency heating device 3, gear pressing device 4, gear transfer truss 5, control cabinet 6, residual magnetism detection device 7, unqualified discharge line 8, and pre-welding heating device 9, all mounted on the support frame 02. Each device is connected to the control cabinet 6 via a signal, and the precise coordination of action timing is achieved through a preset program, eliminating the need for manual intervention in the connection of each process and greatly reducing the risk of human operation.

[0031] like Figure 3 As shown, the gear demagnetizing device 1 includes a demagnetizing device bracket 11, a first detector 13, a gear conveyor belt 14, a demagnetizer 15, a gear loading position, and a gear unloading position 16. The demagnetizing device bracket 11 provides stable support for the overall structure. The gear conveyor belt 14 is horizontally installed on the bracket and passes through the demagnetizer 15 to form a continuous transmission channel. Its two ends correspond to the gear loading position and the gear unloading position 16, respectively. The first detector 13 is installed at the gear loading position, and the demagnetizer 15 is fixed in the middle of the bracket at the position corresponding to the gear transmission path.

[0032] During operation, robot 01 picks up the gear assembly (including shaft gears and sprocket gears) to be processed and places it at the gear loading position. After the first detector 13 detects the gear's arrival, it sends a signal to the control cabinet 6, which then activates the gear transport belt 14 and the demagnetizer 15. The gear moves slowly along the belt and passes through the magnetic field area of ​​the demagnetizer 15, where residual magnetism is effectively eliminated, and finally, it is transported to the gear picking position 16. This structure, through the linkage of automated transport and detection, avoids parts collisions caused by manual handling. The coordinated control of the first detector 13 and the demagnetizer 15 ensures sufficient demagnetization time and uniform demagnetization effect, providing high-quality blanks for subsequent processing and reducing the adverse effects of residual magnetism on press-fitting and welding.

[0033] like Figure 4 As shown, the gear feeding device 2 includes a gear feeding rotating assembly 21, a gear heating feeding assembly 22, a gear picking claw 23, a shaft gear picking claw 24, a shaft gear pressing feeding assembly 25, and a gear transport belt.

[0034] The gear feeding rotating assembly 21 and the gear heating feeding assembly 22 are linked by a gear transmission mechanism. The gear picking claw 23 is driven by a cylinder and installed at the end of the gear heating feeding assembly 22. The shaft gear picking claw 24 is fixedly connected to the linear module of the shaft gear press-fit feeding assembly 25 and can move in the horizontal and vertical directions. The gear conveyor belt is used for the transfer and transmission of the gears.

[0035] After the demagnetized gear reaches the gear picking position 16, the control cabinet 6 issues a command, and the gear feeding rotating assembly 21 rotates 90° clockwise from the zero position, driving the gear heating and feeding assembly 22 to move above the gear. Then, the cylinder on the assembly drives the gear picking claw 23 to descend, grab the gear, reset and transfer it to the gear conveyor belt, and then transfer it to the feeding end of the power frequency heating device 3 via the gear conveyor belt. At the same time, the shaft gear picking claw 24 grabs the shaft gear under the drive of the shaft gear pressing and feeding assembly 25, moves along the preset trajectory to the shaft gear positioning assembly 41 of the gear pressing device 4, and completes the positioning and placement.

[0036] This device enables automated feeding of shaft gears and disc gears in separate, synchronous paths, avoiding deviations and efficiency bottlenecks caused by manual feeding, shortening process connection time, and laying the foundation for improving overall production efficiency.

[0037] like Figure 5 As shown, the power frequency heating device 3 includes a power frequency heating platform 31, a heating component 32, a heating upper induction head 33, an induction head lifting mechanism 34, a material unloading robot component 35, and an upper induction component 36.

[0038] The power frequency heating platform 31 is fixed on the support frame 02. The heating component 32 is embedded inside the heating platform. Its output end is connected to the upper heating induction head 33 through a wire. The power frequency heating platform 31 and the upper heating induction head 33 are arranged vertically to form an upper and lower induction heating structure. The induction head lifting mechanism 34 is a ball screw module, which is fixed to the mounting base of the upper heating induction head 33 and can drive it to rise and fall vertically. The upper induction component 36 is installed above the heating component 32 through a bracket and integrates an infrared temperature sensor. The unloading robot component 35 is a multi-degree-of-freedom pneumatic gripper, which is installed on the side of the power frequency heating platform 31.

[0039] After the gear is transferred to the positioning slot of the power frequency heating table 31, the heating component 32 is activated to generate a high-frequency alternating magnetic field. The induction head lifting mechanism 34 drives the heating upper induction head 33 to descend, so that it maintains an optimal heating gap of 2-3 cm with the gear surface in real time.

[0040] The power frequency heating platform 31 and the heating induction head 33 work together to form a multi-directional three-dimensional heating structure, which synchronously conducts heat to the upper and lower surfaces and inner and outer ring areas of the gear. Compared with the traditional local heating method, this structure reduces the heating time from 2-3 minutes to less than 1 minute, increasing production efficiency by more than 50%. Moreover, the temperature difference between the inner and outer rings of the gear is controlled within a few degrees Celsius, which greatly reduces the risk of material performance degradation caused by local overheating and significantly improves the pass rate of subsequent pressing.

[0041] After heating is complete, the infrared temperature sensor of the upper sensing component 36 moves horizontally above the gear, focuses on detecting its surface temperature and feeds it back to the control cabinet 6. Once the temperature reaches the target, the unloading robot component 35 grabs the gear and transfers it to the gripping area of ​​the gear transfer gantry 5.

[0042] like Figure 6 As shown, the gear pressing device 4 includes a shaft gear positioning assembly 41, a pressing electric cylinder 42, a first drive motor 43, a sprocket gear positioning assembly 44, a pressing robot 45, a shaft gear clamping chuck 46, and a support plate 47. The shaft gear positioning assembly 41 is provided with a sliding groove 411 adapted to the shaft gear for precise positioning of the shaft gear. The shaft gear clamping chuck 46 is installed on the top of the shaft gear positioning assembly 41 for clamping and positioning the shaft gear. The sprocket gear positioning assembly 44 is an annular positioning seat, coaxially arranged with the shaft gear positioning assembly 41. The pressing electric cylinder 42 is connected to the first drive motor 43 through a flange, and its output shaft is connected to the shaft gear positioning assembly 41. The pressing robot 45 is installed on the side of the sprocket gear positioning assembly 44 through a rotary cylinder and can rotate to above the sprocket gear. The support plate 47 is a welded steel plate structure that supports the bottom of the pressing electric cylinder 42.

[0043] After the shaft gear is positioned by the slide groove 411 of the shaft gear positioning assembly 41, the shaft gear clamping chuck 46 tightens and fixes the shaft gear; the preheated disc gear is transferred to the disc gear positioning assembly 44 by the gear transfer gantry 5, and then the clamping manipulator 45 rotates 90° under the drive of the rotary cylinder and rests on the upper surface of the disc gear to achieve auxiliary fixation of the disc gear.

[0044] The control cabinet 6 starts the first drive motor 43, which drives the pressing cylinder 42 to move slowly downward, causing the shaft gear positioning assembly 41 to descend synchronously, so that the shaft gear is accurately pressed into the assembly hole of the plate gear.

[0045] During the pressing process, the pressing force and displacement data are fed back to the control cabinet 6 in real time, and the pressing curve is displayed on the host interface, which makes it easier for operators to judge the pressing quality.

[0046] This structure, through its dual positioning and auxiliary clamping design, ensures pressing accuracy, avoids gear misalignment or damage during pressing, and further improves the processing quality stability of the assembled parts.

[0047] like Figure 7 , Figure 8 As shown, the gear transfer truss 5 includes a first drive module 51, upper and lower parallel racks 52, truss support 53, assembly transport robot 54, assembly rotation assembly 55, two limiting mechanisms 56, a second drive module 58, and a horizontal parallel rack 59.

[0048] The first drive module 51 is a combination of a servo motor and a reducer, which meshes with the upper and lower parallel racks 52 via gears. The upper and lower parallel racks 52 are vertically fixed to the columns of the support frame 02. The truss support 53 is slidably connected to the upper and lower parallel racks 52 via a slider, and can move in the vertical direction. The first drive module 51 is used to drive the truss support 53 to move between the two limit mechanisms 56 along the upper and lower parallel racks 52. The second drive module 58 is also a servo drive structure, which meshes with the horizontal parallel rack 59, and the horizontal parallel rack 59 is horizontally fixed to the crossbeam of the truss support 53. The assembly transport robot 54 is connected to the horizontal parallel rack 59 via a sliding seat, and can move in the horizontal direction. The second drive module 58 is used to drive the assembly transport robot 54 to move along the horizontal parallel rack 59. The assembly rotation component 55 is a rotary cylinder, which is installed at the end of the assembly transport robot 54, and its output shaft is connected to the gripper. The limit mechanism 56 is a limit switch, which is installed at both ends of the upper and lower parallel racks 52.

[0049] During process connection, the first drive module 51 drives the truss support 53 to adjust its height along the upper and lower parallel racks 52, and the second drive module 58 drives the assembly transport robot 54 to move to the target station along the horizontal parallel rack 59.

[0050] When gripping the gear, the assembly transport robot 54 moves to the discharge end of the power frequency heating device 3. After the gripper closes and grips the gear, it is transferred to the gear pressing device 4. After pressing, the assembly transport robot 54 grips the assembly, the assembly rotating component 55 starts to rotate 180°, and after adjusting the posture of the assembly, it is transferred to the residual magnetism detection device 7.

[0051] The limiting mechanism 56 precisely limits the movement range of the truss support 53, preventing damage to the equipment due to overtravel. This truss structure enables efficient and precise transfer between multiple workstations, allowing for parallel operations, further shortening process intervals and improving the overall production pace.

[0052] like Figure 9 As shown, the residual magnetism detection device 7 includes a motion mechanism 71, an I-shaped slide rail 72, a sensor head support 73, a residual magnetism detection sensor head 74, a detection platform 75, and a rotary motor 76.

[0053] The motion mechanism 71 is a linear module, fixedly connected to the I-shaped slide 72, which is horizontally mounted on the support frame 02. The sensor head support 73 is slidably connected to the I-shaped slide 72 and fixed to the slider of the motion mechanism 71. The residual magnetism detection sensor head 74 is mounted on the bottom of the sensor head support 73 and adopts a non-contact design. The detection table 75 is a circular platform, rotatably connected to the support frame 02 through bearings. Its bottom is connected to the output shaft of the rotary motor 76 through a coupling. The rotary motor 76 is used to drive the assembly to rotate.

[0054] After the assembly is transferred to the testing table 75, the rotary motor 76 starts, driving the testing table 75 and the assembly to rotate 360° at a constant speed; at the same time, the motion mechanism 71 drives the induction head support 73 to move horizontally along the I-shaped slide 72, so that the residual magnetism detection induction head 74 moves to the testing area of ​​the assembly, maintaining a millimeter-level detection gap.

[0055] The residual magnetism detection induction head 74 collects residual magnetism data of the assembly in real time and transmits it to the control cabinet 6 for analysis. Compared with the traditional manual handheld detection method, this automated rotary detection design eliminates human operation error, and the millimeter-level gap avoids contact wear between the probe and the assembly, extending the probe's service life by more than 3 times, reducing equipment maintenance costs, and ensuring the accuracy of the detection results, providing a reliable guarantee for the subsequent welding quality.

[0056] like Figure 10 As shown, the non-conforming discharge line 8 includes a residual magnetism analysis element 81, a second drive motor 82, a motion component 83, a robotic arm rotation mechanism 84, a residual magnetism detection unloading robotic arm 85, and a non-conforming discharge belt 86.

[0057] The residual magnetism analysis element 81 is connected to the control cabinet 6 via a signal to receive the detection data from the residual magnetism detection device 7 and determine whether the assembly is qualified. The second drive motor 82 is connected to the lead screw of the motion component 83 and drives it to move along the guide rail. The robotic arm rotation mechanism 84 is a rotary cylinder installed on the slider of the motion component 83. The residual magnetism detection unloading robotic arm 85 is a pneumatic gripper connected to the output shaft of the robotic arm rotation mechanism 84. The non-conforming discharge belt 86 is horizontally installed below the support frame 02 and extends to the non-conforming product collection area outside the equipment.

[0058] When the residual magnetism analysis element 81 determines that the assembly is unqualified, the control cabinet 6 sends a command to start the second drive motor 82. The motion component 83 drives the robot arm rotation mechanism 84 and the residual magnetism detection unloading robot arm 85 to move above the detection table 75. The robot arm rotation mechanism 84 rotates 90° so that the gripper is aligned with the assembly. After the residual magnetism detection unloading robot arm 85 closes and grabs the assembly, the motion component 83 drives it to move above the unqualified discharge belt 86. The gripper releases and places the unqualified assembly on the belt. The unqualified discharge belt 86 starts and transports the unqualified product to the designated collection area.

[0059] This structure enables automated sorting and output of non-conforming products, preventing them from being mixed into subsequent processes, while also facilitating centralized processing and quality traceability of non-conforming products.

[0060] like Figure 11 As shown, the pre-welding heating device 9 includes a heating platform 91, a heating support 92, a lifting cylinder 93, an upper heater 94, a placement fixture 95, and a second detector 96.

[0061] Specifically, the heating platform 91 is fixed to the support frame 02 by the heating support base 92, and the surface is provided with positioning grooves for placing the assembled parts; the lifting cylinder 93 is vertically installed on the upper bracket of the heating platform 91, and its piston rod is fixed to the mounting plate of the upper heater 94, which is used to drive the upper heater 94 to lift and lower relative to the assembled parts placed on the heating platform 91; the upper heater 94 is an electromagnetic heating structure and is set opposite to the heating platform 91; the placement fixture 95 is a bracket made of high temperature resistant material, located on the side of the heating platform 91, and is used to support the preheated assembled parts; the second detector 96 is a photoelectric sensor, installed on the edge of the heating platform 91, and is used to detect whether the assembled parts are in place and send a material picking command.

[0062] Once the residual magnetism test is passed, the assembly is transferred by the gear transfer truss 5 to the positioning slot of the heating platform 91. After the second detector 96 detects that the assembly is in place, it sends a signal to the control cabinet 6, and the lifting cylinder 93 starts to drive the upper heater 94 to descend and approach the surface of the assembly for heating.

[0063] After heating to the preset temperature, the lifting cylinder 93 drives the upper heater 94 to rise and reset, and the assembly transport robot 54 of the gear transfer truss 5 grabs the assembly and transfers it to the placement fixture 95 for welding.

[0064] This heating structure can precisely control the heating temperature and time, ensuring that the components are in the optimal temperature state before welding, further improving the welding qualification rate. At the same time, the automated heating and transfer design avoids the safety risks and quality damage caused by manual contact with high-temperature components.

[0065] Specific steps of multi-station automated gear machining method Based on the above equipment structure, the multi-station automated gear processing method of this embodiment includes the following detailed steps: S1: Demagnetization step. The operator places the shaft gears and disc gears that meet the cleaning standards into the dedicated material box. After starting the equipment, the control cabinet 6 instructs robot 01 to start.

[0066] Robot 01's gripper grasps the gear components in the material box and transfers them one by one to the gear loading position of the gear demagnetizing device 1. After the first detector 13 detects that the gear has arrived, the gear conveyor belt 14 starts, driving the gear to slowly pass through the demagnetizer 15. The demagnetizing magnetic field generated by the demagnetizer 15 eliminates the residual magnetism on the gear surface. When the gear is transferred to the gear picking position 16, the first detector 13 checks again to confirm that the gear demagnetization is complete, and the gear conveyor belt 14 stops, waiting for the loading device to grab it.

[0067] S2: The control cabinet 6 for the feeding and preheating steps instructs the gear feeding device 2 to start, the gear feeding rotating component 21 rotates 90° clockwise, the gear heating feeding component 22 descends, the gear picking claw 23 closes to grab the gear, the component then resets and moves the gear to the gear conveyor belt, and then moves it to the positioning slot of the power frequency heating table 31 of the power frequency heating device 3 via the gear conveyor belt.

[0068] At the same time, the shaft gear picking chuck 24 grabs the shaft gear, and the shaft gear pressing and feeding assembly 25 drives it to move to the shaft gear positioning assembly 41 of the gear pressing device 4, and the shaft gear clamping chuck 46 tightens and fixes the shaft gear.

[0069] When the power frequency heating device 3 is started, the heating component 32 generates a high-frequency alternating magnetic field. The induction head lifting mechanism 34 drives the upper heating induction head 33 to descend to 2-3 cm above the surface of the gear. The power frequency heating platform 31 and the upper heating induction head 33 work together to perform multi-directional three-dimensional heating on the gear.

[0070] Within 1 minute of heating, the inner and outer rings of the gear reach a uniform temperature. After the infrared temperature sensor of the upper sensing component 36 detects that the temperature meets the standard, the unloading robot component 35 grabs the gear and transfers it to the grabbing position of the gear transfer gantry 5.

[0071] S3: In the pressing step, the first drive module 51 and the second drive module 58 of the gear transfer gantry 5 work together to drive the assembly transport robot 54 to move to the gear gripping position. After the gripper closes and grips the gear, it is transferred to the gear positioning assembly 44 of the gear pressing device 4.

[0072] The clamping robot arm 45 rotates 90° and rests against the gear. The control cabinet 6 starts the first drive motor 43, which drives the pressing cylinder 42 to slowly move downward, causing the shaft gear positioning assembly 41 to descend. The shaft gear is then precisely pressed into the mounting hole of the gear. After pressing is completed, the pressing curve shows that it is qualified, the clamping robot arm 45 resets, and the shaft gear clamping chuck 46 is released.

[0073] S4: Inspection and sorting step The assembly transport robot 54 of the gear transfer gantry 5 moves to the gear pressing device 4, grabs the pressed assembly, and after the assembly rotation component 55 rotates 180° to adjust its posture, it is transferred to the inspection table 75 of the residual magnetism detection device 7.

[0074] The rotary motor 76 starts and drives the assembly to rotate 360°. The motion mechanism 71 drives the residual magnetism detection head 74 to move to the detection area to perform non-contact residual magnetism detection with a millimeter-level gap. The detection data is transmitted to the residual magnetism analysis element 81.

[0075] If the assembly is determined to be unqualified, the unqualified discharge line 8 is activated, and the residual magnetic detection unloading robot 85 grabs the unqualified assembly and transfers it to the unqualified discharge belt 86 for output; if it is determined to be qualified, the assembly transport robot 54 of the gear transfer truss 5 grabs the qualified assembly and transfers it to the pre-welding heating device 9.

[0076] S5: After the preheating step is completed, the qualified assembly is placed on the heating platform 91 of the preheating device 9. After the second detector 96 detects that the assembly is in place, the lifting cylinder 93 drives the upper heater 94 to descend and preheat the assembly.

[0077] After heating to the preset temperature, the lifting cylinder 93 drives the upper heater 94 to rise, and the assembly transport robot 54 of the gear transfer gantry 5 grabs the assembly and transfers it to the placement fixture 95. The operator removes the assembly from the placement fixture 95 for subsequent welding. The equipment repeats the above steps to achieve automated processing of large batches of gear assemblies.

[0078] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them; although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications to the technical solutions described in the foregoing embodiments, or equivalent substitutions for some or all of the technical features, do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this application.

Claims

1. A multi-station automated gear machining apparatus, characterized by, The gear demagnetization device (1), the gear feeding device (2), the power frequency heating device (3), the gear press-fitting device (4), the gear transfer truss (5), the control electric cabinet (6), the residual magnetism detection device (7), the unqualified discharge line (8) and the pre-welding heating device (9) are arranged on the support frame (02). The discharge end of the gear demagnetization device (1) is connected with the feeding end of the gear feeding device (2). The gear feeding device (2) is configured to transfer the demagnetized gear to the power frequency heating device (3) and transfer the demagnetized shaft gear to the gear press-fitting device (4). The discharge end of the power frequency heating device (3) is connected with the gear feeding end of the gear press-fitting device (4) through the gear transfer truss (5). The discharge end of the gear press-fitting device (4) is connected with the feeding end of the residual magnetism detection device (7) through the gear transfer truss (5). The unqualified product outlet of the residual magnetism detection device (7) is connected with the unqualified discharge line (8), and the qualified product outlet is connected with the feeding end of the pre-welding heating device (9). The control electric cabinet (6) is connected with each device for controlling each device to act in coordination according to the processing time sequence.

2. The multi-station automated gear machining apparatus of claim 1, wherein, The power frequency heating device (3) comprises a power frequency heating table (31), a heating assembly (32), a heating upper induction head (33), an induction head lifting mechanism (34), a discharging manipulator assembly (35) and a temperature detection assembly (36). The heating assembly (32) is fixedly arranged on the support frame (02), the power frequency heating table (31) and the induction head lifting mechanism (34) are connected to the heating assembly (32), and the power frequency heating table (31) and the heating upper induction head (33) are arranged in a top-to-bottom corresponding mode to form a top-to-bottom induction heating structure. The heating upper induction head (33) is connected to the induction head lifting mechanism (34), and the induction head lifting mechanism (34) is used for driving the heating upper induction head (33) to lift to form a heating gap of 2-3 cm with the surface of the gear placed on the power frequency heating table (31). The temperature detection assembly (36) is integrated with an infrared temperature sensor, which is used for moving horizontally above the gear and focusing on detecting the surface temperature of the gear, and feeding back the temperature signal to the control electric cabinet (6). The discharging manipulator assembly (35) is used for grabbing the gear and transferring the gear to the gear transfer truss (5) after the temperature detection is up to the standard.

3. The multi-station automated gear machining apparatus of claim 1, wherein, The gear demagnetization device (1) comprises a demagnetization device support (11), and a gear conveying belt (14), a demagnetizer (15), a gear feeding position (12), a detector (13) and a gear taking position (16) arranged on the demagnetization device support (11). The demagnetization device support (11) is arranged on the support frame (02), the gear conveying belt (14) is arranged through the demagnetizer (15), and the two ends of the gear conveying belt (14) correspond to the gear feeding position (12) and the gear taking position (16) respectively. The detector (13) is arranged corresponding to the gear loading position (12) to sense the part in-place signal and trigger the demagnetization device to start.

4. The multi-station automated gear machining apparatus of claim 1, wherein, The gear loading device (2) comprises a sheet gear loading rotation assembly (21), a sheet gear heating loading assembly (22), a sheet gear taking clamp (23), a shaft gear taking clamp (24), a shaft gear press loading assembly (25) and a gear conveying belt (26) arranged on the support frame (02); The sheet gear loading rotation assembly (21) is linked with the sheet gear heating loading assembly (22) to drive the sheet gear taking clamp (23) to grab and transfer the sheet gear to the gear conveying belt (26) and then to the power frequency heating device (3) through the gear conveying belt (26); The shaft gear taking clamp (24) cooperates with the shaft gear press loading assembly (25) to grab and transfer the shaft gear to the gear press device (4).

5. The multi-station automated gear machining apparatus of claim 1, wherein, The gear press device (4) comprises a shaft gear positioning assembly (41), a press loading electric cylinder (42), a driving motor, a sheet gear positioning assembly (44), a press mechanical hand (45) and a shaft gear clamping chuck (46) arranged on the support frame (02); The driving motor is drivingly connected with the press loading electric cylinder (42), the press loading electric cylinder (42) is connected with the shaft gear positioning assembly (41), and the shaft gear clamping chuck (46) is arranged on the shaft gear positioning assembly (41) to clamp and position the shaft gear; The press loading electric cylinder (42) is used to drive the shaft gear positioning assembly (41) to press the shaft gear into the sheet gear positioned on the sheet gear positioning assembly (44); The press mechanical hand (45) is rotatably arranged to abut on the sheet gear during the press process.

6. The multi-station automated gear machining apparatus of claim 1, wherein, The gear transfer truss (5) comprises a first driving module (51), an up-and-down parallel rack (52), a truss support (53), a combined piece conveying mechanical hand (54), a combined piece rotation assembly (55), a limiting mechanism one (56), a limiting mechanism two (57), a second driving module (58) and a horizontal parallel rack (59) arranged on the support frame (02); The first driving module (51) is used to drive the truss support (53) to move along the up-and-down parallel rack (52) between the limiting mechanism one (56) and the limiting mechanism two (57); The combined piece rotation assembly (55) is arranged on the combined piece conveying mechanical hand (54) to drive the combined piece to rotate and adjust the posture; The second driving module (58) is used to drive the combined piece conveying mechanical hand (54) to move in the horizontal direction.

7. The multi-station automated gear machining apparatus of claim 1, wherein, The residual magnetism detection device (7) comprises a detection table (75), an induction head support seat (73) and an I-shaped sliding groove (72), a rotating motor (76), a motion mechanism (71) and a residual magnetism detection induction head (74) arranged on the support frame (02); The rotating motor (76) is drivingly connected with the detection table (75) to drive the combined piece to rotate; The I-shaped sliding groove piece (72) is fixedly arranged, the induction head support seat (73) is slidably connected to the I-shaped sliding groove piece (72), and the residual magnetism detection induction head (74) is installed on the induction head support seat (73); The motion mechanism (71) is drivingly connected with the induction head support seat (73), and is used for driving horizontal movement of the induction head support seat (73) to detect residual magnetism of the rotating assembly.

8. The multi-station automated gear machining apparatus of claim 1, wherein, The unqualified discharge line (8) comprises a residual magnetism analysis element (81), a driving motor (82), a motion assembly (83), a mechanical arm rotating mechanism (84), a residual magnetism detection discharging mechanical arm (85) and an unqualified discharge belt (86) arranged on the support frame (02); The driving motor (82) is drivingly connected with the motion assembly (83), the motion assembly (83) is connected with the mechanical arm rotating mechanism (84), the mechanical arm rotating mechanism (84) is drivingly connected with the residual magnetism detection discharging mechanical arm (85), and is used for grabbing unqualified assembly according to a judgment result and outputting the unqualified assembly through the unqualified discharge belt (86).

9. The multi-station automated gear machining apparatus of claim 1, wherein, The pre-welding heating device (9) comprises a heating platform (91), a support seat (92), a lifting cylinder (93), an upper heater (94), a placing tool (95) and a detector (96) arranged on the support frame (02); The support seat (92) is fixed to the support frame (02), the lifting cylinder (93) is installed on the support seat (92), and the lifting cylinder (93) is drivingly connected with the upper heater (94) and is used for driving lifting of the upper heater (94) relative to the assembly placed on the heating platform (91); The placing tool (95) is arranged corresponding to the heating platform (91) and is used for carrying the preheated assembly; The detector (96) is arranged corresponding to the placing tool (95) and is used for detecting whether the assembly is in place and sending a material taking instruction.

10. A multi-station automated gear machining method, characterized by, The multi-station automatic gear machining device of any one of claims 1 to 9 comprises the following sequential steps: S1: demagnetization step: demagnetizing the gear assembly in the gear demagnetization device (1); S2: feeding and preheating step: moving the demagnetized sheet gear to the power frequency heating device (3) for preheating through the gear feeding device (2), and moving the demagnetized shaft gear to the gear press fitting device (4) at the same time; S3: press fitting step: moving the preheated sheet gear to the gear press fitting device (4) through the gear transfer truss (5) to press fit the shaft gear into an assembly; S4: detection and sorting step: moving the press-fitted assembly to the residual magnetism detection device (7) for detection through the gear transfer truss (5), unqualified assemblies are output by the unqualified discharge line (8), and qualified assemblies are moved to the pre-welding heating device (9); S5: pre-welding preheating step: preheating the qualified assembly in the pre-welding heating device (9) for welding.

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