A composite fully automated hot die forging production line for a precision front axle crankshaft

Abstract

The invention discloses a composite fully-automatic hot die forging production line for a precision front axle crankshaft, which mainly comprises 8 forging equipments, 9 robots and 4 transfer tables; the hot bar materials are fully-automatically transferred between the forging equipments according to different workstations by means of the transfer tables by the robots; the R2 robot and the roller forging hand are docked in the air; the forging stations of the 10,000-ton hot die forging press are arranged horizontally; the die frame of the hot die forging press adopts a composite die frame structure of a main die frame and a spare die frame, the main die frame is replaced from the front window, and the spare die frame is pulled out from the side window of the hot die forging press, so as to realize rapid replacement; a spray robot is arranged on the other side of the hot die forging press to realize automatic spraying; the invention can produce both front axles and crankshafts, and is a composite production line for front axles and crankshafts; the whole line adopts a transfer table which can accurately locate and detect incoming materials, and adopts a bus control method to realize full-line automated production, which has the advantages of high production efficiency and low failure rate.

Description

Technical Field

[0001] The present invention relates to a composite fully automated hot die forging production line for a precision front axle crankshaft, which is particularly applicable to the forging field and does not require human involvement in the entire process. The hot bars are fully automatically transferred and transported between forging equipment according to different workstations by robots with the aid of a transfer table. Background Art

[0002] With the deepening of industrial transfer and the development of my country's high-end equipment manufacturing industry, some domestic forging enterprises have made great progress in forging technology, forging equipment level and forging capacity by absorbing and introducing technology, strengthening R&D cooperation and technology accumulation. The main presses for forging the front axle and crankshaft of automobiles currently include friction presses, electric screw presses, hot die forging presses, etc. Among them, the friction press has a simple structure and low price, but has low control accuracy, high failure rate, and low degree of automation, and has become an obsolete product; the electric screw press has a simple structure and high controllability, but poor anti-eccentric load capability, low efficiency, and limited application range. In order to solve the defects of the above two types of equipment, hot die forging presses are widely used. It has the advantages of high frame rigidity, strong anti-eccentric load capability, static pressure forging, and fast slider movement speed, good forging product quality and high production efficiency. It is widely used in the front axle crankshaft composite production line, but this front axle and crankshaft production line basically continues the German technology of the 1980s. This technology has the following 5 defects: 1) Hot die forging hands and conveyor belts are used to transport and convey forgings, among which the loading, unloading and inter-station transfer of forgings on the press are realized by hot die forging hands, and the transmission of forgings between presses is realized by conveyor belts. However, the hot die forging hand is a coordinate structure with low degree of freedom, inflexible operation and high failure rate; while the conveyor belt has low positioning accuracy and long forging conveying time. Therefore, the hot die forging hand and conveyor belt have the disadvantages of high failure rate and low production efficiency. 2) The signal transmission between the equipment adopts a point-to-point mode, relying on manual judgment whether to enter the next automatic operation, with low automation and low production efficiency. 3) When replacing the die, the entire die frame needs to be pulled out, replaced with a new die, and then the die frame is pushed into the press, and then the die is heated to the required forging temperature before the forging production can continue. The die replacement time takes 6-8 hours, which reduces the efficiency of production line conversion and die repair. 4) Due to the large difference in shape between the front axle and the crankshaft, they need to be equipped with die frames respectively, and the manufacturing cost of the die frame is high. 5) The die cooling and lubrication adopts manual spraying, the working environment is harsh, and the product quality is unstable. This technology requires manual participation in the production process, has a low degree of automation, low production efficiency, high failure rate, and difficult to improve product quality, and can no longer meet the current market demand.

[0003] The present invention solves the defects of the above five hot die forging presses and has the following eight technical advantages: 1) A forging-specific robot is used to replace the original hot die forging hand with low automation, and the conveyor belt with low positioning accuracy and long conveying time is eliminated. The entire line adopts a transfer table that can accurately locate and detect incoming materials, and adopts a bus control method to achieve full-line automated production, with high automation, high production efficiency and low failure rate. 2) The 10,000-ton hot die forging press (10) adopts a composite die frame structure of a universal main die frame and a spare die frame. A set of die frames can meet the different product requirements of the front axle and the crankshaft, reducing the cost of die frame use and improving the flexibility of the production line. 3) The R3 operating robot (8) is equipped with a trolley. When replacing the main die frame, the die changing table (9) of the 10,000-ton hot die forging press (10) is equipped with a guide rail. When replacing the main die frame, the R3 operating robot (8) can be pushed out of the die changing table along the guide rail to facilitate the replacement of the main die frame. 4) Each press is equipped with a quick-change device. The mold adopts a hydraulic clamping method, which can realize quick clamping and loosening of the mold. The quick-change device can realize quick mold replacement, and the mold replacement time is shortened to less than half an hour. 5) A spray lubrication robot is used. The spraying method is flexible and the spraying amount is controllable. It can ensure the cooling and lubrication effect of the mold, improve the mold life, and ensure the continuity of automated production. 6) A descaling device is used to remove the oxide scale on the surface of the billet to improve the quality of the forged product. 7) The roll forging bar is directly connected to the roll forging machine operator (5) and the R2 robot (6) in the air, eliminating the forging transfer link, reducing the failure rate of the intermediate link, and shortening the production cycle. 8) The forging direction of the hot die forging press is changed from the original longitudinal forging direction (along the front and back direction of the press) to the transverse forging (along the left and right direction of the press), which is convenient for realizing the quick replacement of the side window mold. The robot clamping the forging into the transverse direction is beneficial to protect the robot and the clamp, and it is also convenient for mold cooling and lubrication. Summary of the invention

[0004] The invention relates to a composite fully automated hot die forging production line for a precision front axle crankshaft, that is, the whole line comprises 8 forging equipments, 9 robots, 4 transfer tables and auxiliary devices; the robots use the transfer tables to fully automatically transfer and transport hot bars between forging equipments according to different workstations; a 10,000-ton hot die forging press is selected as the main forging press; the robot and the roller forging hand dock the hot bars in the air; the forging stations of the hot die forging press are arranged horizontally, the front window is placed with a die changing table, and the side window is placed with a quick changing device matched with a spare die frame; a spray lubrication robot is arranged in the other side window to realize fully automatic all-round spray lubrication; the die frame structure of the hot die forging press adopts a composite die frame structure of a main die frame and a spare die frame, and the structure of the spare die frame determines that the production line can produce both front axles and crankshafts, and belongs to a composite fully automated hot die forging production line.

[0005] The forging stations of the hot forging press are arranged horizontally to realize quick mold change through the quick-change device from the side window, and a spray robot is arranged on the other side window to realize fully automatic all-round spray lubrication and cleaning; the front window is used to replace the main die frame and the R3 robot to feed the hot bar material into the die cavity, and the rear window is used for the robot to take out the forgings; the hot forging press adopts a composite die frame structure of a universal main die frame and a spare die frame. The main die frame is universal, and the spare die frame can be adapted to the forging of the front axle and crankshaft respectively, and is easy to replace or repair; a base with rollers is designed under the R3 operating robot, and a guide rail is designed on the die changing table of the hot forging press. When the main die frame is replaced, the R3 operating robot moves back 3000mm along the guide rail, and after exiting the die changing table, it rotates 90° counterclockwise and then remains stationary to facilitate the replacement of the main die frame. Each press is equipped with a quick-change device to achieve rapid mold replacement, and each press adopts hydraulic clamping to tighten the mold, which shortens the mold change time to less than half an hour; a descaling device is installed on the hot bar before roll forging to remove the oxide skin on the surface of the hot bar; the roll forging bar is directly connected and picked up in the air by the roll forging machine operator and the R2 robot, and the R2 robot clamps the hot bar in the middle position; special forging robots are used to replace the original hot die forging hands with low automation, and the entire line uses a transfer table with precise positioning and incoming material detection function to replace the conveyor belt with low accuracy and long conveying time, and the bus control method is used to realize fully automated production; while the R5 robot takes out the forgings, the R4 spray lubrication robot enters from the side window of the press to clean and spray cooling lubricate the mold. BRIEF DESCRIPTION OF THE DRAWINGS

[0006] Figure 1 It is the general layout of the composite fully automated hot die forging production line for the precision front axle crankshaft;

[0007] Figure 2 This is the general assembly drawing of the hot die forging press die change table and robot base;

[0008] Figure 3 This is a diagram of the die changing table of a hot die forging press;

[0009] Figure 4 This is the R3 robot base diagram;

[0010] Figure 5 This is a diagram of the incoming material detection device at the transfer station;

[0011] Figure 6 This is the hydraulic clamping structure diagram of each press mold. DETAILED DESCRIPTION

[0012] In this embodiment Figure 1It is the general layout of the composite fully automated hot die forging production line for precision front axle crankshaft. The whole line includes 8 forging equipment, namely, medium frequency furnace 1, descaling device 2, roll forging machine 4, roll forging machine operator 5, 10,000-ton hot die forging press 10, trimming press 15, twisting press 21, and correction press 24; 9 robots, namely, R1 robot 3, R2 operating robot 6, R3 operating robot 8, R4 spray lubrication robot 12, R5 operating robot 13, R6 flash removal robot 17, R6 flash removal robot 17, R7 operating robot 18, R8 operating robot 22, and R9 operating robot 26; 4 transfer tables, namely, 1# transfer table 7, 2# transfer table 14, 3# transfer table 19 and 4# transfer table 23; auxiliary devices, including exit guide rails 28, die changing table 9, quick change device and bus control system, etc.

[0013] Production line process flow: After the bar is heated by the medium frequency furnace 1, it is clamped by the R1 robot 3 and sent to the descaling device 2; after the bar is descaled by the descaling device 2, it is transported to the receiving position of the roll forging machine operator 5 through the roller of the descaling device 2; after the roll forging machine operator clamps the bar and completes the roll forging on the roll forging machine 4, the roll forging machine operator 5 retreats to the discharging position;

[0014] The R2 operating robot 6 and the roll forging machine operator 5 perform aerial docking to pick up materials. The R2 operating robot directly clamps the middle part of the bar from the roll forging machine operator and puts it on the 1# transfer table 7;

[0015] The R3 operating robot 8 takes the material from the 1# transfer table 7, and then puts it into the die cavity of the 10,000-ton hot die forging press 10 through the front window of the press for 2-3 passes of forging. After the forging is completed, the R5 operating robot 13 takes the forging out from the rear window of the press and puts it on the 2# transfer table 14. While the R5 robot takes out the forging, the R4 spray lubrication robot 12 enters from the side window of the press to clean the mold and spray cooling and lubricate it. When 2-3 passes of forging are performed on a 10,000-ton hot die forging press, the R3 operating robot and the R5 operating robot 13 also have the function of transferring materials between workstations; the R7 operating robot 18 clamps the forging from the 2# transfer table 14 and places it on the trimming press 15 for trimming. After trimming, the R7 operating robot 18 takes the trimmed forging from the trimming press and places it on the 3# transfer table 19, and then the R6 flash removal robot 17 enters the press from the rear window of the press to remove the flash; when the forging is a crankshaft that needs to be twisted, the R8 operating robot 2 2 The forging is clamped from the 3# transfer table 19 and placed on the twisting press 21. After the twisting is completed, the R8 operating robot takes out the forging from the twisting press and places it on the 4# transfer table 23. When the forging is the front axle and does not need twisting, the R8 operating robot 22 clamps the forging from the 3# transfer table 19 and places it directly on the 4# transfer table 23. The R9 operating robot 26 clamps the forging from the 4# transfer table 23 and places it on the calibration press 24. After the calibration is completed, the R9 operating robot 26 takes out the forging from the press and hangs it on the controlled cooling suspension chain or places it on the discharge conveyor belt.

[0016] In the general layout diagram of the composite fully automated hot die forging production line for the precision front axle crankshaft, the descaling device 2 is in the same straight line with the roll forging operator, and is H5 = 4200mm away from the hot die forging press 10. The descaling device is H1 = 2500mm away from the center line of the medium frequency furnace, and the distance between the two discharge ports of the medium frequency furnace is H2 = 2400mm; the R1 robot 3 is on the center line of the medium frequency furnace, and is L6 = 3000mm away from the roll forging machine 4; the R2 robot 6 is L7 = 4800mm away from the roll forging machine 4, and is The distance between the center line of the initial workstation of the operator 5 is H4=2700mm; the distance between the 1# transfer table 7 and the R2 robot 6 is H3=400mm, L8=2800mm; the normal working position of the R3 robot 8 is H6=300mm, L10=3850mm away from the 10,000-ton hot die forging press 10. The R3 robot works on the die change table 9. When the main die frame is replaced, the R3 robot retreats L9=3000mm and turns 90° to stand still at the dotted position at L9=3000mm in the figure. The distance between the R4 robot 12 and the 10,000-ton hot die forging press is L11=1700mm, H8=3800mm; the distance between the R5 robot 13 and the 10,000-ton hot die forging press is L12=3200mm, H7=300mm; the distance between the 2# transfer table 14 and the R5 robot is L13=2600mm, H10=800mm. The trimming press 15, the twisting press 21 and the correction press 24 are arranged on the same straight line, and the distance H9 from the hot forging press 10 is 2000mm; the trimming press 15 is equipped with a trimming machine quick change device 16, the twisting press 21 is equipped with a twisting machine quick change device 20, and the correction press 24 is equipped with a correction machine quick change device 25. The quick change device cooperates with the mold rapid hydraulic clamping system to realize rapid mold replacement. The position of the R6 robot 17 is L20 = 2300mm, H12 = 1600mm, and it takes out the flash from the trimming press and places the flash on the flash frame; the position of the R7 robot 18 is L14 = 1500mm, H11 = 3000mm, and it is used to transfer and transport forgings between the trimming press and the 2# and 3# transfer tables; the 3# and 4# transfer tables are arranged in the same straight line, and are H13 = H15 = 800mm away from the R7 robot, and the 3# transfer table 19 is L15 = 2500mm away from the R7 robot; the R8 robot 22 The distance from the twisting press 21 is L16=800mm, H14=3000mm; the distance from the 4# transfer table 23 to the R8 robot is L17=2500mm. The R8 robot takes the forgings from the 3# transfer table. If crankshafts are produced, the R8 robot takes out the forgings and puts them on the twisting machine for twisting, and then takes them out from the twisting machine and puts them on the 4# transfer table. If the front axle is produced, the R8 robot directly takes the forgings from the 3# transfer table and puts them on the 4# transfer table; The distance from the R9 robot 26 to the correction press 24 is H16=3000mm, L18=500mm.The distance between trimming press 15 and 10,000-ton hot die forging press 10L3=7000mm, the distance between twisting press 21 and trimming press L4=7000mm, and the distance between correction press and twisting press L5=6000mm. The distance between roll forging machine 4 and hot die forging press 10L2=13000mm, the distance between the outlet of medium frequency heating furnace and roll forging machine 4L1=5500mm, and the operator of roll forging machine 5 retreats L19=4200mm, and docks the hot bar material with R2 robot in the air at this position.

[0017] Figure 2 It is the general assembly drawing of the die changing table and robot base of the hot die forging press. In the figure, number 28 is the exit double guide rail, which is the guide rail used by the R3 robot when the hot die forging press replaces the main die frame to exit the die changing table 9L9=3000mm. The die changing table 9 has a lifting function. When the R3 robot is working, it is lower than the working table of the hot die forging press. Only when the main die frame is replaced, the die changing table 9 is raised to the same height as the table of the hot die forging press; number 29 is the exit guide rail 28 and the double-track connector on the die changing table 9, number 31 is the base with rollers connecting the R3 robot and the die changing table. When the R3 robot is working, the base 31 is fixed on the die changing table 9 by the fixer 30 and the fixer 32, so as to keep the R3 robot fixed during the working process, number 33 is the connector of the die changing table 9 and the hot die forging press 10, and the center distance of the R3 robot to the die changing table 9L=1925mm.

[0018] Figure 3 It is a diagram of a die changing table of a hot forging press. Reference numeral 30′ is a threaded hole corresponding to the fixture 30, and reference numeral 32′ is a threaded hole corresponding to the fixture 32. The R3 robot is fixed to the die changing table 9 by the fixture, so that the R3 robot remains stable during operation.

[0019] Figure 4 This is a diagram of the R3 robot base. Number 27 indicates that there are four fixed bosses of the R3 robot 8, which are arranged at 90 degrees around the weight-reducing circular hole, as shown in the position in the figure. The R3 robot is fixed to the fixed boss 27 by bolts; four rollers are installed at the four corners below the R3 robot base 31, and the rollers move forward and backward along the track direction on the two tracks of the mold changing table 9.

[0020] Figure 5 This is a diagram of the incoming material detection device of the transfer table. The number 34 is a detection rod, the number 35 is a spiral spring, the number 36 is a travel switch, and the number 37 is a forging. Before the incoming material, the detection rod is raised to a height higher than the placement of the forging under the action of the spring. When the forging is placed on the material table, the detection rod is pressed downward, causing the travel switch 36 to rotate an angle and send information to the master control system. After the forging is taken away, the detection rod is reset under the action of the spring; the top of the detection rod is equipped with a bolt, which can be adjusted in height according to the size of the forging.

[0021] Figure 6 It is the hydraulic clamping structure diagram of each press mold, number 38 is the upper main mold frame, number 39 is the upper clamping cylinder, number 40 is the upper spare mold frame, number 41 is the upper mold, number 42 is the lower mold, number 43 is the lower spare mold frame, number 44 is the lower clamping cylinder, number 45 is the lower main mold frame; the upper and lower molds are respectively installed on the upper and lower spare mold frames through mechanical connection, among which the upper spare mold frame is installed to the upper main mold frame through the upper clamping cylinder, and the upper spare mold frame is installed to the lower main mold frame through the lower clamping cylinder. When changing the mold, the clamping cylinder rod is loosened, and the T-head is rotated 90°, so that the spare mold frame and the mold can be pulled out of the press together for quick mold change; and each press mold adopts hydraulic clamping to realize rapid clamping and loosening of the mold, and is pulled out together with the mold quick-change mold frame to replace the mold.

[0022] The above description is only a preferred embodiment of the present invention, and any changes made according to the claims of the present invention should fall within the scope of the present invention.

Claims

1. A precision front axle crankshaft composite fully automated hot die forging production line, that is, the entire line includes 8 forging equipment, 9 robots, 4 transfer tables and auxiliary devices. The transfer table has a precise positioning function; the robot uses the transfer table to automatically transfer and transport hot bars between forging equipment according to different workstations; the main forging press uses a 10,000-ton hot die forging press; the roll forging machine operator clamps the bar and rolls it on the roll forging machine; the robot and the roll forging machine operator dock the hot bar in the air, and the R2 operating robot directly clamps it from the roll forging machine operator After the bar material reaches the middle part, it is placed on the 1# transfer table, and the R3 operating robot takes the material from the 1# transfer table; the forging station of the hot die forging press is arranged horizontally, with the die changing table placed on the front window and the quick change device matching the spare die frame placed on the side window; the spray lubrication robot is arranged on the other side window to realize the full-automatic all-round spray lubrication and cleaning function; the die frame structure of the hot die forging press adopts a composite die frame structure of the main die frame and the spare die frame. The structure of the spare die frame determines that this production line can produce both front axles and crankshafts, which belongs to a composite fully automatic hot die forging production line; When the forging is a crankshaft that needs to be twisted, the R8 operating robot clamps the forging from the 3# transfer table and places it on the twisting press; The die changing table has a lifting function. When the R3 robot is working, it is lower than the working table of the hot die forging press. Only when the main die frame is replaced, the die changing table rises to the same height as the table of the hot die forging press. When the R3 operating robot is working, the base is fixed on the die changing table by two fixtures to keep the R3 operating robot stationary during the working process. A base with four rollers is designed under the R3 operating robot. A guide rail is designed on the die changing table of the hot die forging press. When replacing the main die frame, the R3 operating robot moves back 3000mm along the guide rail, exits the die changing table, rotates 90° counterclockwise and then stands still, so as to facilitate the replacement of the main die frame; Each press is equipped with a quick-change device to achieve rapid mold replacement, and each press mold clamping adopts hydraulic clamping to shorten the mold change time to less than half an hour. The hydraulic clamping structure of the press mold includes an upper main mold frame, an upper clamping cylinder, an upper spare mold frame, an upper mold, a lower mold, a lower spare mold frame, a lower clamping cylinder and a lower main mold frame. The upper and lower molds are respectively installed on the upper and lower spare mold frames through mechanical connections, wherein the upper spare mold frame is installed to the upper main mold frame through the upper clamping cylinder, and the lower spare mold frame is installed to the lower main mold frame through the lower clamping cylinder. When changing the mold, the clamping cylinder rod is loosened, and the T-head is rotated 90°, so that the spare mold frame and the mold can be pulled out of the press together for quick mold change. Each press mold adopts hydraulic clamping to achieve rapid clamping and loosening of the mold, and is pulled out together with the mold quick-change mold frame to replace the mold.

2. A precision front axle crankshaft composite fully automated hot die forging production line as claimed in claim 1, characterized in that: The front window of the hot die forging press is used to replace the main die frame and the R3 robot to feed the hot bar into the hot die forging press cavity, and the rear window is used for the robot to take out the forgings.

3. A precision front axle crankshaft composite fully automated hot die forging production line as claimed in claim 1, characterized in that: The hot die forging press adopts a universal main die frame and a spare die frame. The main die frame is universal, and the spare die frame can be adapted to the forging of the front axle and crankshaft respectively, and is easy to replace or repair.

4. A precision front axle crankshaft composite fully automated hot die forging production line as claimed in claim 1, characterized in that: The hot bar is descaled using a descaling device before roll forging to remove the oxide scale on the surface of the hot bar.

5. A precision front axle crankshaft composite fully automated hot die forging production line as claimed in claim 1, characterized in that: The entire line is operated by robots without the need for human intervention. The entire line uses a transfer table with precise positioning and incoming material detection function to replace the conveyor belt with low precision and long delivery time. At the same time, bus control is used to achieve fully automated production.

6. A precision front axle crankshaft composite fully automated hot die forging production line as claimed in claim 5, characterized in that: The initial position of the detection rod of the transfer table exceeds the height at which the forging is placed. The detection rod detects that the forging is pressed downward, causing the travel switch to rotate an angle and send information to the main control system to remove the forging, and the detection rod returns to the initial position; a bolt is installed on the top of the detection rod, which can be adjusted in height according to the different sizes of forgings.

7. A precision front axle crankshaft composite fully automated hot die forging production line as claimed in claim 1, characterized in that: While the R5 robot is taking out the forging, the R4 spray lubrication robot enters from the side window of the press to spray cool, lubricate and clean the die.

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