Stabilizer intelligent stamping production unit and process flow

Abstract

This invention relates to an intelligent stamping production unit and process flow for centralizers. The intelligent stamping production unit for centralizers includes: a safety enclosure forming a production and processing area; a loading pallet disposed within the production and processing area, the loading pallet being configured to hold workpieces to be processed; a processing device disposed within the production and processing area, the processing device being configured to process the workpieces from the loading pallet; an unloading pallet disposed within the production and processing area, the unloading pallet being configured to hold the workpieces processed by the processing device; and a transport robot capable of moving within the production and processing area to transport the workpieces between the loading pallet, the processing device, and the unloading pallet.

Description

Technical Field

[0001] This invention relates to the field of petrochemical equipment manufacturing technology, and more particularly to an intelligent stamping production unit for centralizers. This invention also relates to an intelligent stamping production process for centralizers. Background Technology

[0002] Centralizers are key components in the petrochemical industry, primarily used to ensure that the internal working parts of downhole tools, valves, and piping systems are always in a precise concentric position, avoiding problems such as uneven wear, vibration, and jamming.

[0003] Traditional stamping production of centralizers primarily relies on manual operation. Currently, semi-automated production methods using centralizers also exist. However, even in semi-automated production, operators still need to enter the processing area to manually install workpieces onto the processing equipment, or manually remove finished workpieces, using simple installation tools. Furthermore, operators must manually feed the workpieces into quenching and annealing equipment for cooling.

[0004] This work method results in a slow production cycle and low production efficiency, making it impossible to meet the demands of large-scale production. Specifically, the installation and removal of workpieces require manual operation, necessitating equipment downtime. On the one hand, manual operation is relatively slow. On the other hand, downtime leads to long periods of equipment idle time and low utilization.

[0005] In addition, because manual installation of workpieces is prone to positioning errors, the accuracy of the produced centralizers is inconsistent, which affects their performance in the well.

[0006] Manual operation requires operators to have direct contact with the stamping equipment and close proximity to quenching, annealing, and cooling equipment. This leads to serious safety hazards. Furthermore, the large amount of manual labor involved results in high labor intensity and high labor costs.

[0007] In addition, the equipment layout in traditional production and processing areas is unreasonable, and the area occupied is large, resulting in low space utilization and insufficient use of workshop space. Summary of the Invention

[0008] This invention proposes an intelligent stamping production unit for centralizers, which can be used to solve at least one of the above-mentioned problems. This invention also proposes an intelligent stamping production process for centralizers.

[0009] According to a first aspect of the present invention, a centralizer intelligent stamping production unit is provided, comprising: a safety fence forming a production processing area within the safety fence; a loading pallet disposed within the production processing area, the loading pallet being configured to hold workpieces to be processed; a processing device disposed within the production processing area, the processing device being configured to process workpieces from the loading pallet; a unloading pallet disposed within the production processing area, the unloading pallet being configured to hold workpieces processed by the processing device; and a transport robot capable of moving within the production processing area to transport the workpieces between the loading pallet, the processing device, and the unloading pallet.

[0010] The aforementioned equipment enables fully automated operation in the production and processing area, eliminating the need for manual operation and thus improving work efficiency and reducing safety risks.

[0011] Preferably, the processing device includes a hydraulic press, which is located in the middle of the production processing area, dividing the production processing area into a loading area and a unloading area. The loading pallet is located in the loading area, and the unloading pallet is located in the unloading area. The conveying robot includes a loading robot and an unloading robot. The loading robot moves in the loading area to transport the workpiece in the loading pallet to the hydraulic press, and the unloading robot moves in the unloading area to transport the workpiece in the hydraulic press to the unloading pallet.

[0012] Preferably, the processing device further includes an annealing machine disposed in the loading area, the annealing machine being configured to perform annealing processing on the workpiece, and the annealing machine being disposed between the loading tray and the hydraulic press in a clockwise or counterclockwise direction.

[0013] Preferably, the workpiece has a non-uniform shape in the circumferential direction, and the centralizer intelligent stamping production unit further includes an orientation mechanism configured to orient the workpiece in the circumferential direction; wherein the orientation mechanism is set independently of the loading pallet, annealing machine and hydraulic press, and the loading robot can transport the workpiece between the loading pallet, annealing machine and hydraulic press and the orientation mechanism, or wherein the orientation mechanism is integrated into the loading pallet, annealing machine or hydraulic press.

[0014] Preferably, the processing device further includes a quenching machine disposed in the unloading area, the quenching machine being configured to perform quenching processing on the workpiece, and the quenching machine being disposed between the hydraulic press and the unloading tray in a clockwise or counterclockwise direction.

[0015] Preferably, the processing device further includes a cooling device disposed in the unloading area, the cooling device being configured to cool the workpiece, and the cooling device being disposed between the quenching machine and the unloading tray in a clockwise or counterclockwise direction.

[0016] Preferably, the intelligent stamping production unit of the stabilizer further includes a detection device disposed above the loading pallet and / or unloading pallet, the detection device being configured to determine the number and / or position of the workpieces in the loading pallet and / or unloading pallet.

[0017] Preferably, each transport robot includes a gripping mechanism for gripping workpieces, the gripping mechanism comprising at least two independent gripping units capable of alternately placing and gripping workpieces for the processing device.

[0018] Preferably, the portion of the safety fence adjacent to the loading pallet and / or unloading pallet has an access opening; wherein the loading pallet and / or unloading pallet is configured to enter and exit the production processing area through the access opening, or wherein the centralizer intelligent stamping production unit further includes a workpiece transport device, the workpiece transport device being configured to enter and exit the production processing area through the access opening to place workpieces in the loading pallet or remove workpieces from the unloading pallet.

[0019] According to a second aspect of the present invention, a smart stamping production process for a centralizer is proposed, which can be executed using the aforementioned smart stamping production unit for a centralizer. The smart stamping production process for a centralizer includes transporting workpieces between the loading pallet, the processing device, and the unloading pallet via the transport robot.

[0020] Preferably, the intelligent stamping production unit for the centralizer includes at least two loading trays. When the number of workpieces in one of the loading trays is lower than the expected minimum, the loading tray is moved out of the production area to replenish the workpieces, and the transport robot is moved to the other loading tray to pick up workpieces; or when the number of workpieces in the loading tray is lower than the expected minimum, a workpiece transport device is moved into the production area to replenish the workpieces in the loading tray.

[0021] Preferably, the intelligent stamping production unit for the centralizer includes at least two unloading trays. When the number of workpieces in one of the unloading trays exceeds the expected maximum value, the unloading tray is moved out of the production processing area to remove the workpieces, and the transport robot places the workpieces into the other unloading tray. Alternatively, when the number of workpieces in the unloading tray exceeds the expected maximum value, a workpiece transport device enters the production processing area to remove the workpieces from the unloading tray. Attached Figure Description

[0022] The invention will be described in more detail below with reference to the accompanying drawings.

[0023] Figure 1 A schematic diagram of an embodiment of the centralizer intelligent stamping production unit according to the present invention is shown.

[0024] Figure 2 A schematic diagram of an embodiment of the gripping mechanism of a transport robot in a centralizer intelligent stamping production unit according to the present invention is shown.

[0025] Figure 3 A schematic diagram of an embodiment of the angle orientation device in the intelligent stamping production unit of the centralizer according to the present invention is shown.

[0026] In the accompanying drawings, the same parts use the same reference numerals. The drawings are not drawn to scale. Detailed Implementation

[0027] The invention will now be further described with reference to the accompanying drawings.

[0028] Figure 1 An embodiment of the centralizer intelligent stamping production unit (hereinafter referred to as "equipment") 1 of the present invention is shown.

[0029] The device 1 includes a safety fence 10, within which a production and processing area is formed. The safety fence 10 generally encloses a rectangular production and processing area. The safety fence 10 may include a metal mesh protective fence, a safety light curtain, and an emergency stop button.

[0030] The safety fence 10 may be equipped with one or more (e.g., two) safety doors 11. The safety doors 11 are normally closed and are opened only when operator access to the production area is required. Operators may enter the production area as needed for cleaning and maintenance.

[0031] Equipment 1 may include a processing device disposed within the production and processing area. The processing device is configured for processing workpieces. The processing device may include one or more hydraulic presses. The hydraulic presses can be used to perform stamping processing on the workpieces. Figure 1 In the example shown, two hydraulic presses 40A and 40B are provided. Hydraulic presses 40A and 40B can be arranged adjacent to each other along a first transverse direction. They can share a single hydraulic station 40. The hydraulic station 40 is located between hydraulic presses 40A and 40B.

[0032] The nominal pressure of the hydraulic press is not less than 30 tons, the stamping speed is adjustable from 50 to 300 mm / s, and the stroke accuracy is not greater than ±0.02 mm.

[0033] Hydraulic presses 40A and 40B can be located in the center of the production area, dividing the area into a loading area A1 and a unloading area A2. Since hydraulic presses 40A and 40B are arranged along a first transverse direction, the loading area A1 and unloading area A2 are arranged along a second transverse direction perpendicular to the first transverse direction. The loading area A1 and unloading area A2 can also be generally rectangular in shape. Safety barriers 10 can be equipped with corresponding safety gates 11 for the loading area A1 and unloading area A2, respectively.

[0034] Equipment 1 also includes one or more loading trays. These loading trays can be used to hold workpieces awaiting processing. Figure 1 In the example shown, two loading trays 20A and 20B are provided. They are arranged adjacent to each other along a first direction on one side of the loading area A1. The loading trays 20A and 20B are arranged opposite to the hydraulic presses 40A and 40B, with free space left in the loading area A1 between them.

[0035] The processing apparatus may also include one or more annealing machines (annealing furnaces) 30 disposed within the loading area A1. The annealing machines 30 can be used to anneal the workpieces. Figure 1 In the example shown, two annealing machines 30 are provided. These two annealing machines 30 are arranged adjacent to each other along the second transverse direction. The annealing machines 30 can be positioned between the loading trays 20A and 20B and the hydraulic presses 40A and 40B in a clockwise or counterclockwise direction. Free space is left in the loading area A1 between the loading trays 20A and 20B, the hydraulic presses 40A and 40B, and the annealing machines 30.

[0036] It should be understood that the workpiece to be processed by the stabilizer usually has a non-uniform shape in the circumferential direction. Multiple edges or any other desired and appropriate local structures can be distributed at intervals in the circumferential direction of the workpiece.

[0037] In this case, device 1 may also include an angle orientation mechanism. This angle orientation mechanism can be used to orient the workpiece circumferentially so that the workpiece of the stabilizer has a defined circumferential orientation and can be precisely aligned with the mold. For example, special structures such as openings or protrusions on the workpiece can be oriented in a defined direction.

[0038] Figure 3A schematic structural diagram of the angle orientation mechanism 110 is shown. The angle orientation mechanism 110 includes a frame base 111 supported on the ground and a rotary table 113 mounted above a top plate of the frame base 111. The angle orientation mechanism 110 may also include a rotary servo motor 112 mounted below the top plate of the frame base 111. The rotary servo motor 112 can be used to drive the rotary table 113 to rotate circumferentially. The angle orientation mechanism 110 may also include a support platform 114 fixedly mounted on the rotary table 113. The support platform 114 can rotate with the rotary table 113 and is used to place a workpiece thereon. Thus, the workpiece can be rotated circumferentially accordingly.

[0039] The angle orientation mechanism 110 may further include a through-beam switch transmitter 115 and a through-beam switch receiver 116, spaced apart and disposed above the top plate of the frame base 111. The through-beam switch transmitter 115 and the through-beam switch receiver 116 sandwich the rotary table and the support table and are centered relative to the rotation axis of the rotary table 113. The contour shape of the workpiece is detected by the through-beam switch transmitter 115 and the through-beam switch receiver 116. When the contour shape of the workpiece is detected to be axially symmetrical, the workpiece is determined to be in the desired correct orientation direction.

[0040] In one example, the angle orientation mechanism may be set independently of the loading pallets 20A and 20B, the annealing machine 30, and the hydraulic presses 40A and 40B. For example, the angle orientation mechanism may be positioned clockwise or counterclockwise between the loading pallets 20A and 20B and the annealing machine 30. Alternatively, the angle orientation mechanism may be positioned clockwise or counterclockwise between the annealing machine 30 and the hydraulic presses 40A and 40B.

[0041] Alternatively, the orientation mechanism can be integrated into the loading pallets 20A and 20B, the annealing machine 30, or the hydraulic presses 40A and 40B.

[0042] Equipment 1 may also include one or more unloading trays disposed within the unloading area A2. The unloading trays can be used to hold workpieces that have been processed by the processing device. Figure 1 In the example shown, two discharge trays 70A and 70B are provided. They are arranged adjacent to each other along the second direction on one side of the discharge area A2. The discharge trays 70A and 70B can be placed on one side of the hydraulic presses 40A and 40B. Free space is left in the discharge area A2 between them.

[0043] The processing apparatus may also include one or more quenching machines (quenching furnaces) 50 disposed within the unloading area A2. The quenching machine 50 can be used to perform quenching processing on the workpiece. Figure 1In the example shown, two quenching machines 50 are provided. These two quenching machines 50 are arranged adjacent to each other along a second transverse direction. The quenching machines 50 can be positioned clockwise or counterclockwise between the hydraulic presses 40A and 40B and the unloading trays 70A and 70B. Free space is left within the unloading area A2 surrounded by the unloading trays 70A and 70B, the hydraulic presses 40A and 40B, and the quenching machines 50.

[0044] The processing apparatus may also include a cooling device 60 disposed within the unloading area A2. The cooling device 60 may be configured to cool the quenched workpiece. The cooling device 60 may be a water tank integrated with a lifting and positioning platform. The workpiece can be placed on the lifting and positioning platform, and the water in the tank can submerge the workpiece to cool it by lowering the platform. The cooling device 60 may be disposed between the quenching machine 50 and the unloading trays 70A and 70B in a clockwise or counterclockwise direction. The cooling device 60 may be arranged relatively spaced from the hydraulic presses 40A and 40B. Free space is provided within the unloading area A2 surrounded by the unloading trays 70A and 70B, the hydraulic presses 40A and 40B, the quenching machine 50, and the cooling device 60.

[0045] like Figure 1 As shown, the safety fence 10 is provided with a cooling device opening 13. The cooling device 60 can pass through the cooling device opening 13, so that it is partially within the production and processing area and partially outside the production and processing area.

[0046] Equipment 1 may also include a transport robot that can move within the production and processing area. The transport robot can transport workpieces between loading pallets, processing devices, and unloading pallets.

[0047] Specifically, the transport robots may include a loading robot 80A and a unloading robot 80B. The loading robot 80A can move within the free space of the loading area A1 and transport the workpieces in the loading trays 20A and 20B to the annealing machine 30, hydraulic presses 40A and 40B for processing. The unloading robot 80B can move within the free space of the unloading area A2 to transport the workpieces in the hydraulic presses 40A and 40B to the quenching machine 50, the cooling device 60, and the unloading trays 70A and 70B.

[0048] The loading robot 80A and unloading robot 80B can move clockwise or counterclockwise to transport workpieces.

[0049] The loading robot 80A and the unloading robot 80B can move freely or along a track.

[0050] The loading robot 80A and unloading robot 80B can be six-axis articulated robots with a load capacity of not less than 10kg and a repeatability of not more than ±0.05mm.

[0051] Each transport robot (including loading robot 80A and unloading robot 80B) may include a gripping mechanism 81 for grasping workpieces. For example... Figure 2 As shown, the gripping mechanism 81 includes a laterally extending mounting plate 81 and one or more independent gripping units mounted below the mounting plate 81. Figure 2 In the example shown, two grabbing units are set up.

[0052] Each gripping unit may include a drive cylinder 812, a support structure 813 driven by the drive cylinder 812, and gripping fingers 814 extending longitudinally downward from the support structure 813. The gripping unit may be provided with multiple sets (e.g., three sets) of drive cylinders, support structures, and gripping fingers. The drive cylinder 812 can cause the gripping fingers 814 to retract relative to each other radially or expand away from each other to achieve gripping or releasing of the workpiece.

[0053] Since the workpieces that have undergone annealing and quenching have very high temperatures, each gripping unit preferably includes a heat shield 815 to mitigate the adverse effects of high temperatures on the gripping unit. The heat shield 815 may surround the drive cylinder 812 and the support structure 813, and allow the gripping fingers 814 to extend from the lower end of the heat shield 815 to contact the workpiece.

[0054] Preferably, a window is provided on the side of the heat insulation cover 815 to facilitate the extension and retraction of the drive cylinder 812.

[0055] Each gripping unit can alternately place and grip workpieces for the processing device to improve work efficiency.

[0056] For example, when the loading robot 80A moves to the loading pallets 20A and 20B, one of the gripping units (gripping unit I) in the gripping mechanism of the loading robot 80A can grip a workpiece from the loading pallets 20A and 20B, while keeping the other gripping unit (gripping unit II) idle. When the loading robot 80A moves to the idle annealing machine 30 that has already undergone annealing (at this time, another annealing machine may be annealing another workpiece), the idle gripping unit II grips the workpiece that has already undergone annealing on the annealing machine 30, and gripping unit I places the workpiece that has just been gripped from the loading pallets 20A and 20B but has not yet undergone annealing onto the annealing machine 30 for annealing. When the loading robot 80A moves to one of the hydraulic presses 40A and 40B that has completed the stamping process, its gripping unit II can place the annealed but not yet stamped workpiece onto the hydraulic press 40A or 40B. Afterward, the loading robot 80A can return to the loading pallets 20A and 20B for the next round of transport when both gripping units are idle.

[0057] For example, when the unloading robot 80B moves to one of the hydraulic presses 40A and 40B that has already completed the stamping process, one of the gripping units (gripping unit III) in the gripping mechanism of the unloading robot 80B can grip a workpiece that has completed the stamping process from the hydraulic presses 40A and 40B, while keeping the other gripping unit (gripping unit IV) idle. When the unloading robot 80B moves to the idle quenching machine 50 that has completed the quenching process, the idle gripping unit IV can grip a workpiece that has already been quenched on the quenching machine 50, while gripping unit III can place a workpiece that has just been gripped from the hydraulic presses 40A and 40B but has not yet been quenched onto the quenching machine 50 for quenching. When the unloading robot 80B moves to the cooling device 60, gripping unit III can grip a workpiece that has already been cooled on the cooling device 60, while gripping unit IV can place a workpiece that has just been quenched but has not yet been cooled onto the cooling device 60 for cooling. When the unloading robot 80B moves to the unloading trays 70A and 70B, the gripping unit III can place the cooled workpieces onto the unloading trays 70A and 70B. Afterward, the unloading robot 80B can return to the hydraulic presses 40A and 40B for the next round of transport when both gripping units are idle.

[0058] The above-described transport process enables rapid transport of workpieces. During this process, all processing devices do not need to be stopped, thus improving the utilization rate of each device.

[0059] In addition, the device 1 may also include a detection device 90 disposed above the loading pallets 20A, 20B and / or unloading pallets 70A, 70B. The detection device may be a vision detection device, such as a 3D vision positioning device. The detection device 90 can be used to determine the number and / or position of workpieces in the loading pallets 20A, 20B and / or unloading pallets 70A, 70B. The control system can control the transport robot to move and grasp and release workpieces based on the number and / or position of workpieces in the loading pallets 20A, 20B and / or unloading pallets 70A, 70B detected by the detection device 90.

[0060] As an alternative or addition, appropriate detection devices can also be installed on the transport robot.

[0061] Preferably, such as Figure 1 As shown, the portion of the safety fence 10 adjacent to the loading pallets 20A, 20B and / or unloading pallets 70A, 70B may be provided with an access opening 12. This access opening 12 can be used for replenishing workpieces on the loading pallets 20A, 20B and / or removing workpieces from the unloading pallets 70A, 70B. This will be described in detail below in conjunction with the process flow.

[0062] The aforementioned access opening 12 can be located in the lower half of the safety fence 10, keeping the upper half of the safety fence 10 closed. The access opening 12 can be configured to be normally open, or it can be equipped with a corresponding door that can be opened when needed.

[0063] The equipment 1 also includes a power supply device and a control device 100 installed outside the safety fence 10. The power supply device can be used to supply power to various devices within the production and processing area. Operators can monitor and control the various devices within the production and processing area through the control device 100.

[0064] The intelligent stamping production process of the centralizer of the present invention can be implemented using the above-mentioned equipment 1. The following is an embodiment of the intelligent stamping production process of the centralizer of the present invention.

[0065] The detection device 90 detects the quantity and / or position of workpieces in the loading trays 20A and 20B. Based on the detected quantity and / or position of workpieces in the loading trays 20A and 20B, the control system controls the loading robot 80A to approach the loading trays 20A and 20B to grab the workpieces, and transports the grabbed workpieces to the annealing machine 30 for annealing. At the same time, the loading robot 80A grabs the workpieces that have already undergone annealing on the annealing machine 30 and sends them to the hydraulic presses 40A and 40B for stamping.

[0066] When the number of workpieces in loading pallets 20A or 20B is detected to be lower than the expected minimum (e.g., 0-3), the control system can control the workpiece transport device to enter the loading area A1 through the aforementioned inlet / outlet 12 to replenish the workpieces in loading pallets 20A or 20B where the number of workpieces is lower than the expected minimum. After replenishment, the workpiece transport device can leave the loading area A1 again through the inlet / outlet 12. The workpiece transport device can return to the workpiece replenishment area to replenish the workpieces to be processed. This workpiece replenishment area can be equipped with additional automated equipment to replenish the workpieces to be processed. Alternatively or additionally, this workpiece replenishment area can be accessed by an operator to manually replenish the workpieces to be processed on the workpiece transport device.

[0067] Alternatively or additionally, when the number of workpieces in loading trays 20A or 20B is detected to be lower than the expected minimum (e.g., 0-3), the control system can cause loading trays 20A or 20B with the lower number of workpieces to leave the loading area A1 through the inlet / outlet 12 and enter the workpiece replenishment area. At this time, additional automated equipment can directly replenish the workpieces to be processed in loading trays 20A or 20B with the lower number of workpieces. Alternatively or additionally, this workpiece replenishment area can be accessed by an operator to manually replenish the workpieces to be processed in loading trays 20A or 20B with the lower number of workpieces.

[0068] It is important to understand that when the expected minimum value is 0, the control system can control the loading robot 80A to pick up a workpiece from another location in loading trays 20A or 20B based on the detection result. When the expected minimum value is not 0, the control system can issue an alarm and still control the loading robot 80A to pick up a workpiece from a loading tray 20A or 20B where the number of workpieces is lower than the expected minimum value, until the number of workpieces in that loading tray 20A or 20B is 0.

[0069] In addition, the control system can also control the unloading robot 80B to grab the stamped workpieces from the hydraulic presses 40A and 40B and transport them to the quenching machine 50 for quenching. Simultaneously, the unloading robot 80B grabs the quenched workpieces from the quenching machine 50 and sends them to the cooling device 0. At the cooling device 60, the unloading robot 80B grabs the cooled workpieces from the cooling device 60 and simultaneously places the freshly quenched workpieces into the cooling device 60 for further cooling. Afterward, the unloading robot 80B can send the cooled workpieces to the unloading trays 70A and 70B and release them.

[0070] The detection device 90 detects the quantity and / or position of workpieces in the unloading trays 70A and 70B. Based on the detected quantity and / or position of workpieces in the unloading trays 70A and 70B, the control system controls the unloading robot 80B to approach the unloading trays 70A and 70B where workpieces are to be released.

[0071] When the number of workpieces in the unloading trays 70A and 70B exceeds the expected maximum value, the control system can control the workpiece transport device to enter the unloading area A2 through the aforementioned inlet / outlet 12 and remove the workpieces from the unloading trays 70A or 70B where the number exceeds the expected maximum value. After removal, the workpiece transport device can leave the unloading area A2 again through the inlet / outlet 12. The workpiece transport device can return to the workpiece storage area to release the processed workpieces. This workpiece storage area can be equipped with additional automated equipment to release the processed workpieces from the storage device. Alternatively or additionally, the workpiece storage area can be accessed by operators to manually release the processed workpieces from the workpiece transport device.

[0072] Alternatively or additionally, when the number of workpieces in unloading trays 70A and 70B exceeds the expected maximum value, the control system can cause the unloading trays 70A or 70B with the excess workpieces to leave the unloading area A2 through the inlet / outlet 12 and enter the workpiece storage area. At this time, other automated equipment can directly release and store the completed workpieces in the unloading trays 70A or 70B with the excess workpieces. Alternatively or additionally, this workpiece replenishment area can be accessed by an operator to manually release and store the completed workpieces in the unloading trays 70A or 70B with the excess workpieces.

[0073] It is important to understand that when the expected maximum value is the full capacity of the unloading pallet (e.g., 50), the control system can control the unloading robot 80B to release workpieces to another location in unloading pallets 70A or 70B based on the detection result. When the expected maximum value is lower than the full capacity of the unloading pallet, the control system can issue an alarm and still control the unloading robot 80B to release workpieces to unloading pallets 70A or 70B where the number of workpieces exceeds the expected maximum value, until the number of workpieces in unloading pallets 70A or 70B reaches the full capacity.

[0074] In this invention, the workpiece is generally cylindrical. In loading pallets, processing devices, unloading pallets, transport robots, and other devices, the workpiece is always placed vertically with its axis perpendicular to it.

[0075] In this invention, the loading tray and unloading tray can be designed in layers, with each layer able to hold multiple workpieces, thereby increasing storage capacity.

[0076] The aforementioned equipment 1 and process flow enable intelligent and automated processing of the centralizer, eliminating the need for operators to enter the production area and requiring no downtime except for maintenance. This improves the efficiency of equipment 1, increases processing accuracy, and reduces safety hazards (achieving zero accidents) and labor costs.

[0077] Furthermore, the aforementioned device 1 allows for a more rational layout, improving the delivery efficiency of the transport robot while reducing the footprint of device 1, thus enhancing space utilization. The footprint can be no more than 5200mm × 5200mm, increasing space utilization by approximately 40% or more.

[0078] In one specific embodiment, the equipment 1 and process flow described above by the present invention can increase production efficiency to approximately 720 units in 8 hours, with a production cycle of approximately 40 seconds per unit. Traditional manual production has a production efficiency of approximately 200 units in 8 hours, with a production cycle of approximately 144 seconds per unit. Therefore, an output increase of approximately 260% is achieved.

[0079] In one specific embodiment, the product qualification rate can be increased to approximately 99.7% using the equipment 1 and process flow described above. The qualification rate of products produced manually in the traditional way is only about 95%. Thus, a product quality improvement of approximately 4.7% is achieved.

[0080] In one specific embodiment, the equipment 1 and process flow described above by the present invention can reduce labor costs from 3 people / shift to 1 person / shift. This reduces labor costs by approximately 67%. Simultaneously, the labor intensity for operators is reduced by over 80%.

[0081] In one specific embodiment, the equipment utilization rate can be increased from about 60% to about 95% by using the above-described equipment 1 and process flow of the present invention. This results in an increase of approximately 35% in equipment utilization.

[0082] In one specific embodiment, the waste rate can be reduced from about 3% to about 0.5% using the above-described equipment 1 and process flow of the present invention. This results in a waste rate reduction of approximately 83%.

[0083] Although the invention has been described with reference to preferred embodiments, various modifications can be made and components can be replaced with equivalents without departing from the scope of the invention. In particular, the technical features mentioned in the various embodiments can be combined in any manner as long as there is no structural conflict. The invention is not limited to the specific embodiments disclosed herein, but includes all technical solutions falling within the scope of the claims.

Claims

1. A centralizer intelligent stamping production unit, comprising: A safety fence, within which a production and processing area is formed; A loading tray is set in the production and processing area, and the loading tray is constructed to hold the workpieces to be processed. A processing device is provided in the production and processing area, the processing device being configured to process workpieces from the loading pallet; A feeding tray is provided within the production and processing area, the feeding tray being configured to hold workpieces processed by the processing device; and A transport robot capable of moving within the production and processing area to transport the workpiece between the loading pallet, processing device, and unloading pallet.

2. The intelligent stamping production unit for centralizers according to claim 1, characterized in that, The processing device includes a hydraulic press, which is located in the middle of the production and processing area. The production and processing area is divided into a loading area and a unloading area by the hydraulic press. The loading tray is located in the loading area and the unloading tray is located in the unloading area. The transport robot includes a loading robot and a unloading robot. The loading robot moves in the loading area to transport the workpiece in the loading pallet to the hydraulic press, and the unloading robot moves in the unloading area to transport the workpiece in the hydraulic press to the unloading pallet.

3. The intelligent stamping production unit for the centralizer according to claim 2, characterized in that, The processing device further includes an annealing machine disposed in the loading area. The annealing machine is configured to perform annealing processing on the workpiece. The annealing machine is disposed between the loading tray and the hydraulic press in a clockwise or counterclockwise direction.

4. The intelligent stamping production unit for centralizers according to claim 3, characterized in that, The workpiece has a non-uniform shape in the circumferential direction, and the centralizer intelligent stamping production unit also includes an orientation mechanism, which is configured to orient the workpiece in the circumferential direction. The orientation mechanism is independent of the loading pallet, annealing machine, and hydraulic press. The loading robot can transport the workpiece between the loading pallet, annealing machine, hydraulic press, and orientation mechanism. The orientation mechanism is integrated into the feeding tray, annealing machine, or hydraulic press.

5. The intelligent stamping production unit for centralizers according to any one of claims 2 to 4, characterized in that, The processing device also includes a quenching machine disposed in the unloading area. The quenching machine is configured to perform quenching processing on the workpiece. The quenching machine is disposed between the hydraulic press and the unloading tray in a clockwise or counterclockwise direction.

6. The intelligent stamping production unit for centralizers according to claim 5, characterized in that, The processing device also includes a cooling device disposed in the unloading area. The cooling device is configured to cool the workpiece and is disposed between the quenching machine and the unloading tray in a clockwise or counterclockwise direction.

7. The intelligent stamping production unit for centralizers according to any one of claims 1 to 6, characterized in that, The intelligent stamping production unit for the centralizer also includes a detection device disposed above the loading pallet and / or unloading pallet, the detection device being configured to determine the number and / or position of the workpieces in the loading pallet and / or unloading pallet.

8. The intelligent stamping production unit for centralizers according to any one of claims 1 to 7, characterized in that, Each transport robot includes a gripping mechanism for grasping workpieces, the gripping mechanism comprising at least two independent gripping units capable of alternately placing and grasping workpieces for the processing device.

9. The intelligent stamping production unit for centralizers according to any one of claims 1 to 8, characterized in that, The portion of the safety fence adjacent to the loading pallet and / or unloading pallet has an access opening. The loading pallet and / or unloading pallet are configured to enter and exit the production and processing area through the access opening, or The intelligent stamping production unit with a centralizer also includes a workpiece transport device. The workpiece transport device is configured to enter and leave the production and processing area through the inlet and outlet openings to place workpieces in the loading tray or remove workpieces from the unloading tray.

10. A smart stamping production process for a centralizer, which can be executed using a smart stamping production unit for a centralizer according to any one of claims 1 to 9, the smart stamping production process for a centralizer comprising transporting workpieces between the loading pallet, the processing device and the unloading pallet by the transport robot.

11. The intelligent stamping production process for the centralizer according to claim 10 is characterized in that the intelligent stamping production unit for the centralizer includes at least two loading trays; when the number of workpieces in one of the loading trays is lower than the expected minimum, the one loading tray is removed from the production area to replenish the workpieces, and the transport robot is dispatched to the other loading tray to pick up workpieces; or When the number of workpieces in the loading pallet is lower than the expected minimum, the workpiece transport device enters the production and processing area to replenish the workpieces in the loading pallet.

12. The intelligent stamping production process for the centralizer according to claim 10 or 11, characterized in that, The intelligent stamping production unit with a centralizer includes at least two unloading trays. When the number of workpieces in one unloading tray exceeds the expected maximum value, one of the unloading trays is moved out of the production area to remove the workpieces, and the transport robot places the workpieces into the other unloading tray; or When the number of workpieces in the unloading tray exceeds the expected maximum value, the workpiece transport device enters the production and processing area to remove the workpieces from the unloading tray.

Images