A turbocharger intermediate shell machining automation system and machining method

Abstract

The present invention provides a turbocharger intermediate shell machining automation system and machining method, including: lathe machining equipment, used for lathe machining the outer circle, end face and inner hole of the two ends of the blank to be machined; a machining center, the lathe machining equipment is transported to the machining center by a seven-axis robot on a ground rail; an automatic measuring device, the semi-finished products finely machined by the machining center are transported to the automatic measuring device by a seven-axis robot on a ground rail; an automatic deburring device, the semi-finished products that have passed the measurement are transported to the automatic deburring device by a robot arm; an automatic honing device, the semi-finished products that have completed automatic deburring are transported to the automatic honing device by a robot arm. The turbocharger intermediate shell machining automation system and machining method of the present invention realizes highly automated integration, automatic measurement and compensation, and is suitable for batch product production. Compared with traditional production lines, it saves manpower input and the turnover time of each process, and improves labor efficiency.

Description

Technical Field

[0001] The invention relates to the technical field of fully automatic production of numerical control machining, and in particular to an automated machining system and a machining method for a turbocharger intermediate shell. Background Art

[0002] The turbocharger intermediate housing requires a series of processing steps from cutting to finished product. With the increase in labor costs, companies urgently need to provide automation to reduce labor costs. However, in actual production operations, workpieces need to be processed individually and through multiple processes, and the same workpiece often has multiple surfaces to be processed. How to transport the workpiece through each station one by one and adjust the angle of the workpiece so that the workpiece can be processed on multiple surfaces has become an urgent problem that needs to be solved. Summary of the invention

[0003] In order to solve the above problems, the present invention provides a turbocharger intermediate shell machining automation system and method, which combines lathe machining, machining center machining, inspection, deburring and honing processes, realizes highly automated integration, automatic measurement and compensation, and is suitable for batch product production. Compared with traditional production lines, it saves manpower input and the turnaround time of each process, and improves labor efficiency.

[0004] In order to achieve the above purpose, a technical solution adopted by the present invention is:

[0005] A turbocharger intermediate housing machining automation system comprises: a lathe machining device, which is used to perform lathe machining on the outer circles, end faces and inner holes of the blank to be machined; a machining center, the lathe machining device is transported to the machining center by a seven-axis robot on a ground rail, and the machining center is used to perform fine machining on the semi-finished products output by the lathe machining device; an automatic measuring device, the semi-finished products finely machined by the machining center are transported to the automatic measuring device by the seven-axis robot on the ground rail, and the automatic measuring device is used to detect the finely machined semi-finished products and feed back the measurement results to a control system to realize automatic tool wear compensation; an automatic deburring device, the semi-finished products that have passed the measurement are transported to the automatic deburring device by a robot arm; and an automatic honing device, the semi-finished products that have completed automatic deburring are transported to the automatic honing device by a robot arm.

[0006] Furthermore, the automatic measuring device includes a two-dimensional code etching mechanism, and the control system is electrically connected to the lathe processing equipment, the machining center, the automatic measuring device, the automatic deburring device and the automatic honing device.

[0007] Furthermore, the lathe processing equipment is a lathe, and the lathe is a CSD300 series parallel dual-spindle CNC lathe.

[0008] Furthermore, the machining center is a DNM5705 machining center.

[0009] The present invention also provides a method for machining a turbocharger intermediate shell based on any one of the above turbocharger intermediate shell machining automation systems, comprising the following steps: OP10 loading, the blank to be machined is cast from gray iron material; OP20 lathe machining, the outer circle at both ends, the end face and the inner hole of each of the blanks to be machined are rough-machined by the lathe machining equipment to obtain a first semi-finished product; OP30 machining center, the first semi-finished product is transported from the lathe machining equipment to the machining center by a ground rail seven-axis robot, the hole of the first semi-finished product is finely machined to obtain a second semi-finished product; OP40 automatic measurement, the second semi-finished product is transported to the automatic measuring device by the ground rail seven-axis robot to detect the dimensions processed in the OP20 and OP30 steps, and the measurement results are fed back to the control system, and the control system realizes automatic tool wear compensation; OP50 automatic deburring, the second semi-finished product that has passed the measurement is transported to the automatic deburring device by the robot arm to remove the burrs to obtain the third semi-finished product; and OP60 automatic honing, the third semi-finished product is transported to the automatic honing device by the robot arm to automatically hone the center hole, and the final product is output by the robot arm.

[0010] Furthermore, the OP20 also includes placing the first semi-finished product in a cleaning machine of the lathe processing equipment for spot cleaning, removing internal iron filings, and drying before transporting it to the processing center; and the OP30 also includes spot cleaning the second semi-finished product, removing internal iron filings, and drying before transporting it to the automatic measuring device.

[0011] Furthermore, the OP40 further comprises etching a QR code on the surface of each second semi-finished product that passes the inspection after the automatic measurement is completed, and storing the dimension measurement result in association with the QR code in the control system.

[0012] Furthermore, it also includes OP70 sampling inspection, manually sampling the final product to obtain a sampling sample, testing the sampling sample to obtain sampling data, and comparing and analyzing the sampling data with the test data corresponding to the QR code of the sampled product.

[0013] The above technical solution of the present invention has the following advantages compared with the prior art:

[0014] (1) The present invention provides a turbocharger intermediate housing machining automation system and method, which combines lathe machining, machining center machining, inspection, deburring and honing processes, and achieves highly automated integration, automatic measurement and compensation, and is suitable for batch product production. Compared with traditional production lines, it saves manpower input and the turnaround time of each process, and improves labor efficiency.

[0015] (2) The present invention provides a turbocharger intermediate shell machining automation system and method, wherein the automatic measuring device includes a two-dimensional code etching mechanism, which can detect the semi-finished product and output the detection data in the form of a two-dimensional code to the control system for storage, so as to facilitate the tracking of product quality in the future.

[0016] (3) The present invention provides a turbocharger intermediate shell machining automation system and machining method, wherein the control system includes a tool compensation control module, which can realize automatic tool wear compensation according to the measurement results of the automatic measuring device, thereby ensuring the stability of the intermediate shell machining automation system.

[0017] (4) The present invention provides a turbocharger intermediate shell machining automation system and method. The transportation between the various processing equipment is carried out by a seven-axis ground-rail robot. The robot has a fast moving speed and does not occupy ground space. Compared with the automation line of traditional equipment components, a large amount of space is saved. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] The technical solutions and beneficial effects of the present invention will be made apparent by describing in detail the specific embodiments of the present invention in conjunction with the accompanying drawings.

[0019] Figure 1 The figure shows a structure diagram of a turbocharger intermediate housing machining automation system according to an embodiment of the present invention;

[0020] Figure 2 Shown is a flow chart of a turbocharger intermediate housing machining method according to an embodiment of the present invention;

[0021] Figure 3 The figure shows a process layout diagram of a turbocharger intermediate housing machining method according to an embodiment of the present invention.

[0022] 1 lathe processing equipment, 2 machining center, 3 automatic measuring device, 4 automatic deburring device, 5 automatic honing device, 6 cleaning mechanism, 7 ground rail seven-axis robot, 8 robot arm, 81 robot arm control cabinet, 9 finished product output mechanism, 91 sampling inspection table. DETAILED DESCRIPTION

[0023] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative work are within the scope of protection of the present invention.

[0024] This embodiment provides a turbocharger intermediate shell machining automation system, such as Figure 1As shown, it includes a lathe processing equipment 1, a machining center 2, an automatic measuring device 3, an automatic deburring device 4, an automatic honing device and a control system. The lathe processing equipment 1 is transported to the machining center 2 by a ground rail seven-axis robot 7, the machining center 2 is transported to the automatic measuring device 3 by the ground rail seven-axis robot 7, the automatic measuring device 3 is transported to the automatic deburring device 4 by a robot arm 8, and the automatic deburring device 4 is transported to the automatic honing device 5 by the robot arm 8. The control system is electrically connected to the lathe processing equipment 1, the machining center 2, the automatic measuring device 3, the automatic deburring device 4 and the automatic honing device 5.

[0025] The lathe processing equipment 1 is a lathe, and the lathe is a CSD300 series parallel dual-spindle CNC lathe. The lathe processing equipment 1 is used to perform lathe processing on the outer circles, end faces and inner holes of the blank to be processed. Preferably, the lathe processing equipment 1 is preferably composed of two dual-spindle CNC lathes, and each dual-spindle CNC lathe is provided with a cleaning mechanism 6 to complete the cleaning and drying tasks of the first semi-finished product after processing by the dual-spindle CNC lathe. Each cleaning mechanism 6 is located below one of the dual-spindle CNC lathes, and the manipulator provided by the dual-spindle CNC lathe can be used to perform loading and unloading operations on the cleaning mechanism 6.

[0026] The machining center 2 is used to perform fine machining on the semi-finished product output by the lathe processing equipment 1 to obtain a second semi-finished product. The machining center 2 is a DNM5705 machining center. Considering space utilization and production efficiency, the machining automation system preferably has four machining centers. A cleaning mechanism 6 is set under each machining center to remove iron filings generated during the machining process and avoid crushing of the workpiece during the handling process by the manipulator. The cleaning mechanism 6 at this station can use the manipulator of the machining center to load and unload the cleaning mechanism 6.

[0027] The control system includes a data acquisition module, a tool compensation control module, a storage module and a display module which are sequentially connected to the control module. The data acquisition module is used to collect the production data of the intermediate shell machining automation system and feed the production data back to the control module. The control module controls the tool compensation control module to perform tool compensation or store the production data in the storage module. The display module is used to display the production data. The management personnel can view the production data at any time through the display module to realize remote monitoring. The second semi-finished product finely processed by the machining center 2 is transported to the automatic measuring device 3 by the ground rail seven-axis robot 7. The automatic measuring device 3 is used to detect the second semi-finished product after fine processing and feed the measurement results back to the control system. The tool compensation control module realizes automatic tool wear compensation. The automatic measuring device 3 also includes a two-dimensional code etching mechanism, which is used to etch the detection data of each second semi-finished product on the second semi-finished product in the form of a two-dimensional code and store it in the storage module of the control system. The automatic measuring device 3 can simultaneously undertake the measurement work of two second semi-finished products, and perform size detection on two intermediate shells, detecting one and caching one. After the inspection is completed, the control system automatically removes the unqualified second semi-finished products, and uses the robot arm 8 to move the qualified second semi-finished products to the automatic deburring device 4 for deburring. The movement of the robot arm 8 is controlled by the robot control system in the robot control cabinet 81, and the robot control cabinet 81 is electrically connected to the control system.

[0028] The automatic deburring device 4 is compatible with the deburring operation of two types of workpieces. The deburred workpiece is transported to the automatic honing device 5 by the robot arm 8, and the honing workpiece is transported to the finished product output mechanism 9 by the robot arm 8. On the finished product output mechanism 9, the workpieces are placed and transported according to the workpieces corresponding to the two lathes and four machining centers. A sampling table 91 is provided on one side of the finished product output mechanism 9 for sampling the processed workpieces. The stability of the turbocharger intermediate shell machining automation system can be judged by the sampling results to ensure product quality.

[0029] The present invention also provides a method for machining a turbocharger intermediate shell based on the above turbocharger intermediate shell machining automation system, such as Figures 2-3 As shown, the process includes the following steps: OP10 loading, OP20 lathe processing, OP30 machining center processing, OP40 automatic measurement, OP50 automatic deburring, OP60 automatic honing and OP70 sampling inspection.

[0030] The blank to be processed OP10 is cast from gray iron material and is loaded into the lathe processing equipment 1 by manual loading.

[0031] OP20 performs lathe processing on the outer circles, end faces and inner holes of each of the blanks to be processed through the lathe processing equipment 1. The processed workpiece is grabbed by the robot arm 8 and put into the cleaning mechanism 6. After internal fixed-point cleaning, removal of internal iron filings and drying, the robot arm 8 grabs the cleaned workpiece to the outside of the cleaning mechanism 6. After switching, the workpiece to be cleaned is placed in the cleaning mechanism 6, and the cleaned workpiece is placed on the conveyor line to obtain the first semi-finished product.

[0032] The first semi-finished product of OP30 is transported to the machining center 2 by the seven-axis robot 7 on the ground track, and the hole of the first semi-finished product is processed by the machining center to obtain the second semi-finished product. The cleaning mechanism 6 under the machining center 2 performs fixed-point cleaning on the second semi-finished product, removes internal iron filings, and dries it before transporting it to the automatic measuring device 3.

[0033] OP40 is automatically measured, and the second semi-finished product is transported to the automatic measuring device 3 by the ground rail seven-axis robot 7 to detect the dimensions processed in the OP20 and OP30 steps, and the measurement results are fed back to the control system, and the control system realizes automatic tool wear compensation. After the automatic measurement is completed, the two-dimensional code etching mechanism of the automatic measuring device 3 etches a two-dimensional code on the surface of each second semi-finished product with qualified dimensions, and the dimension measurement results are associated with the two-dimensional code and stored in the control system.

[0034] OP50 automatically removes burrs, and the second semi-finished product that has passed the measurement is transported to the automatic deburring device 4 by the robot arm 8 to remove the burrs, thereby obtaining the third semi-finished product.

[0035] The third semi-finished product OP60 is transported to the automatic honing device 5 by the robot arm 8 to automatically hone the center hole, and the final product is output by the robot arm 8.

[0036] OP70 sampling inspection, manually sampling the final product to obtain sampling samples, testing the sampling samples to obtain sampling data, and comparing and analyzing the sampling data with the test data corresponding to the QR code of the sampled product. The stability of the turbocharger intermediate housing machining method is obtained through the comparative analysis results.

[0037] The above description is only an exemplary embodiment of the present invention, and does not limit the scope of patent protection of the present invention. Any equivalent structure or equivalent process transformation made by using the contents of the present invention specification and drawings, or directly or indirectly applied in other related technical fields, are also included in the scope of patent protection of the present invention.

Claims

1. A method for machining a turbocharger intermediate shell based on a turbocharger intermediate shell machining automation system, characterized in that: A turbocharger intermediate shell machining automation system is used, and the turbocharger intermediate shell machining automation system includes Lathe processing equipment, used for lathe processing of the outer circle, end face and inner hole of the blank to be processed; A machining center, wherein the lathe machining equipment transports the first semi-finished product after lathe machining to the machining center via a ground rail seven-axis robot, and the machining center is used to perform fine machining on the first semi-finished product output by the lathe machining equipment; An automatic measuring device, the second semi-finished product finely processed by the machining center is transported to the automatic measuring device by a ground rail seven-axis robot, and the automatic measuring device is used to detect the finely processed second semi-finished product and feed back the measurement result to the control system to realize automatic tool wear compensation; An automatic deburring device, wherein the qualified second semi-finished product is transported to the automatic deburring device by a robotic arm to obtain a third semi-finished product; and An automatic honing device, wherein the third semi-finished product after automatic deburring is transported to the automatic honing device by a mechanical arm; The automatic measuring device includes a two-dimensional code etching mechanism, the control system includes a storage module and a tool compensation control module, and the control system is electrically connected to the lathe processing equipment, the processing center, the automatic measuring device, the automatic deburring device and the automatic honing device; The processing method of the turbocharger intermediate housing comprises the following steps: OP10 loading, the blank to be processed is cast from gray iron material; OP20 lathe processing, rough turning the outer circles at both ends, the end faces and the inner holes of each of the blanks to be processed by means of a lathe processing equipment to obtain a first semi-finished product; OP30 machining center, the first semi-finished product is transported from the lathe machining equipment to the machining center through the ground rail seven-axis robot, and the hole of the first semi-finished product is finely machined to obtain the second semi-finished product; OP40 automatic measurement, the second semi-finished product is transported to the automatic measuring device by the ground rail seven-axis robot to detect the dimensions processed in the OP20 and OP30 steps, and the measurement results are fed back to the control system, and the control system realizes automatic tool wear compensation; OP50 automatic deburring, the qualified second semi-finished product is transported to the automatic deburring device by a robot arm to remove burrs, and a third semi-finished product is obtained; and OP60 automatic honing, the third semi-finished product is transported to the automatic honing device by a robotic arm to automatically hone the center hole, and the final product is output by the robotic arm; The OP40 further includes etching a two-dimensional code on the surface of each second semi-finished product that passes the test after the automatic measurement is completed, and storing the size measurement result in association with the two-dimensional code in the control system.

2. The method for processing a turbocharger intermediate housing according to claim 1, characterized in that: The lathe processing equipment is a lathe, and the lathe is a CSD300 series parallel double-spindle CNC lathe.

3. The method for processing a turbocharger intermediate housing according to claim 1, characterized in that: The machining center is a DNM5705 machining center.

4. The method for processing a turbocharger intermediate housing according to claim 1, characterized in that: The OP20 further includes placing the first semi-finished product in a cleaning machine of the lathe processing equipment for fixed-point cleaning, removing internal iron filings, and transporting the first semi-finished product to the processing center after drying; and The OP30 also includes spot cleaning the second semi-finished product, removing internal iron filings, and transporting it to the automatic measuring device after drying.

5. The method for processing a turbocharger intermediate housing according to claim 1, characterized in that: It also includes OP70 sampling inspection, manually sampling the final product to obtain a sampling sample, testing the sampling sample to obtain sampling inspection data, and comparing and analyzing the sampling inspection data with the inspection data corresponding to the QR code of the sampling sample.

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