An automated production system and method for mining drill pipes with multi-station operation of a robot

Abstract

The present invention relates to the production field of short drill pipes such as mine drill pipes and through drill pipes, in particular to an automated production system and method for mine drill pipes with multi-station operation by robots, which includes a mechanical subsystem and a communication control subsystem. The mechanical subsystem includes process units and robots. The robots transfer the pipe materials among different process units. Multiple groups of process units for pipe material transfer completed by the same robot are arranged around a circle with the robot as the center. Multiple robots are placed side by side at different workstations, and the corresponding circumferential parts overlap. The communication control subsystem controls the robots to transfer the pipe materials from the loading area to each process unit in sequence, and finally obtain the finished products in the unloading area; at the same time, it also controls the process units to process or detect the pipe materials. The present invention also includes a method. The present invention not only improves the utilization rate of the site area by using the double-circle overlapping area design, but also realizes the full automation and intelligence of drill pipe production, improving the labor efficiency and output.

Description

Technical Field

[0001] The present invention relates to the production field of short drill pipes such as mine drill pipes and horizontal directional drilling drill pipes, and in particular to an automated production system and method for mine drill pipes with multi-station operation by robots. Background Art

[0002] Drill pipes are important tools for drilling operations of drilling rigs. Whether it is an oil drilling rig, a coal mine gas drainage drilling rig, or a horizontal directional drilling construction rig, drill pipes are required for their drilling operations. Structurally, drill pipes can be divided into three parts: male connectors, female connectors, and pipe bodies. The male connectors and female connectors are respectively welded to both ends of the pipe body, and threads are machined on the outside of the male connectors and the inside of the female connectors. The basic production process of mine drill pipes and horizontal directional drilling drill pipes mainly includes: connector processing, pipe body heat treatment, welding of connectors and pipe bodies, weld heat treatment, quality inspection, etc.

[0003] China is a major drill pipe producer, but the old method used in drill pipe production lines more than twenty years ago is still in use, that is, a semi-automatic straight-line layout assembly line production mode with manual operation of machinery. Under the background of highly developed information technology, rapid popularization of PLC technology, and active promotion of Industry 4.0, this method has become very backward, specifically reflected in the high proportion of manual operation in the process, especially in the connection of process links, low production efficiency; large floor area of the production line, and high labor costs caused by a large number of operators. Summary of the Invention

[0004] The purpose of the present invention is to provide an automated production system for mine drill pipes with multi-station operation by robots, mainly to solve the problems existing in the above-mentioned prior art. It can realize the automation of mine drill pipe production, the intelligence of some process procedures, save the floor area of the production line, reduce the number of operators, improve the stability of the drill pipe process quality, and reduce the production cost of drill pipes.

[0005] In order to achieve the above purpose, the technical solution adopted by the present invention is to provide an automated production system for mine drill pipes with multi-station operation by robots, which is characterized in that it includes a mechanical subsystem and a communication control subsystem;

[0006] The mechanical subsystem includes multiple groups of process units and one or more robots; the robot transfers the pipe materials among different process units, and the process units process or detect the pipe materials; multiple groups of process units for which the pipe materials are transferred by the same robot are arranged on a circle with the robot as the center;

[0007] The communication control subsystem controls the robot to transfer the pipe materials from the loading area, sequentially to each process unit, and finally obtain finished products in the unloading area; the process units process or detect the pipe materials under the control of the communication control subsystem.

[0008] Furthermore, when there are multiple robots, the circular portions corresponding to different robots overlap to form an overlapping area; in the overlapping area, an upward handover area and a downward handover area are set for transferring and handing over the pipe material between two robots.

[0009] Furthermore, the process unit includes a radial module and a processing device or a detection device; the radial module transfers the pipe material handed over by the robot to the processing equipment for processing, or transfers the pipe material to the detection equipment for detection; when the processing or detection is completed, the radial module transfers the pipe material back to the robot for processing by the robot.

[0010] Furthermore, the processing equipment is a pipe thread lathe, a friction welding machine, a medium frequency induction heating furnace, a spray quenching ring, a fan, a spray device and a grinding machine.

[0011] Furthermore, the pipe thread lathe and the radial module constitute a pipe end face processing unit or a weld turning unit; the friction welding machine and the radial module constitute a friction welding unit; the medium frequency induction heating furnace, the spray quenching ring and the radial module constitute a weld quenching unit; the medium frequency induction heating furnace and the radial module constitute a weld tempering unit; the fan, the spray device and the radial module constitute a weld cooling unit; the grinder and the radial module constitute a weld grinding unit.

[0012] Furthermore, the detection equipment includes a three-point bending test machine, a hydraulic system and a magnetic particle flaw detection device.

[0013] Furthermore, the three-point bending test machine, the hydraulic system and the radial module constitute a pressure test unit; the magnetic particle flaw detection equipment and the radial module constitute a magnetic particle flaw detection unit.

[0014] Furthermore, the radial module is composed of a stand, a roller group, a ball screw pair, a baffle, a servo motor, a variable frequency motor and a pneumatic chuck; the servo motor, the roller group and the ball screw pair are fixed on the stand; the baffle, the variable frequency motor and the pneumatic chuck are fixed on the ball screw pair and are driven by the servo motor to move along the direction of the ball screw pair; the pipe material placed by the robot is supported by the roller group and the baffle on the ball screw pair; the pneumatic chuck clamps the pipe material, the variable frequency motor drives the pipe material to rotate, and the servo motor drives the pipe material to transfer.

[0015] Further, the communication control subsystem includes an information acquisition module, a control execution module, and a data output and display module; the information acquisition module collects the states of the process unit and the robot and transmits them to the control execution module for calculation and analysis; the control execution module issues control instructions to the process unit or the robot according to the results of the calculation and analysis; the data output and display module is connected to the control execution module to record or display the results of the calculation and analysis of the control execution module in real time.

[0016] Further, the information acquisition module is an optoelectronic sensor; the optoelectronic sensor is arranged at each of the process unit and the robot for collecting the state information of the process unit and the robot.

[0017] Further, the control execution module includes a programmable controller, a memory, an input / output sub-module, and a power supply; the programmable controller calculates and analyzes the information from the information acquisition module by using the memory and displays the results through the input / output sub-module; the power supply provides power support for the programmable controller, the memory, and the input / output sub-module.

[0018] Further, the data output and display module includes a monitoring terminal, an alarm, and a data memory; the control execution module transmits the analysis and calculation results to the monitoring terminal and triggers the alarm to act according to the analysis and calculation results; the data memory is used to store the analysis and calculation results from the control execution module.

[0019] The present invention also provides a method for producing a mine drill pipe by using a mine drill pipe automatic production system with a robot multi-station operation as described above, which is characterized by including the steps:

[0020] Step S101, initializing the mechanical subsystem and the communication control subsystem, and setting the operation rhythm and idle signal of each process unit;

[0021] Step S102, using the feeding mechanism to move the pipe material to the feeding area, and the feeding area issues a completion signal;

[0022] Step S103, after the communication control subsystem detects the completion signal of the feeding area, enter step S104, otherwise continue to wait;

[0023] Step S104, when the process unit of the next process issues an idle signal, dispatch the robot to transfer the pipe material to the process unit of the next process;

[0024] Step S105, after the communication control subsystem detects that the pipe material is in place in the process unit, it schedules the process unit to process or inspect the pipe material; after the process unit completes the processing or inspection, it sends a completion signal to the communication control subsystem;

[0025] Step S106, the communication control subsystem detects the completion signal of the pipe material on the process unit. If the next process is the process unit, it jumps to step S104; if the next process is the blanking area, then after the blanking area sends an idle signal, the communication control subsystem schedules the robot to transfer the pipe material to the blanking area to complete the processing of the pipe material.

[0026] The present invention also provides a method for producing a mine drill pipe using the above-mentioned automatic production system for mine drill pipes with multi-station operation of a robot, which is characterized by including the steps:

[0027] Step S201, initialize the mechanical subsystem and the communication control subsystem, and set the operation rhythm and idle signal of each process unit;

[0028] Step S202, use the feeding mechanism to move the pipe material to the feeding area, and the feeding area sends a completion signal;

[0029] Step S203, after the communication control subsystem detects the completion signal of the feeding area, it enters step S204, otherwise it continues to wait;

[0030] Step S204, when the process unit of the next process sends an idle signal, schedule the robot to transfer the pipe material to the process unit of the next process;

[0031] Step S205, after the communication control subsystem detects that the pipe material is in place in the process unit, it schedules the process unit to process or inspect the pipe material; after the process unit completes the processing or inspection, it sends a completion signal to the communication control subsystem;

[0032] Step S206, the communication control subsystem detects the completion signal of the pipe material on the process unit. If the next process is the process unit, it jumps to step S204; if the next process is the upper transfer area or the lower transfer area, it enters step S207; if the next process is the blanking area, then after the blanking area sends an idle signal, the communication control subsystem schedules the robot to transfer the pipe material to the blanking area to complete the processing of the pipe material;

[0033] Step S207: After the upstream handover area or the downstream handover area sends an idle signal, the communication control subsystem schedules the aforementioned robot to transfer the pipe material to the upstream handover area or the downstream handover area and hand it over to the subsequent robot.

[0034] Step S208: After the pipe material is in place in the upstream handover area or the downstream handover area, the upstream handover area or the downstream handover area sends a completion signal, and jumps to Step S204.

[0035] Further, the process units that the pipe material passes through from the feeding area to the discharging area to form the finished product are in sequence: pipe body end face machining unit, friction welding unit, weld quenching unit, first weld tempering unit, second weld tempering unit, weld cooling unit, first weld turning unit, second weld turning unit, weld grinding unit, pressure test unit, and magnetic particle flaw detection unit.

[0036] In view of the above technical features, compared with the traditional mechanical assembly line method, the present invention has the following advantages:

[0037] 1. The present invention realizes full-automatic control of drill pipe production, achieves intelligence in process links such as precise positioning of weld heat treatment, precise tempering of welds, and cutting of internal flash, and the output is significantly increased: a single line can produce 240 drill pipes per day.

[0038] 2. The double-circle overlapping area design used in the present invention improves the utilization rate of the site area by more than 30% compared with the traditional assembly line design.

[0039] 3. The present invention adopts a design of two robots with eleven workstations, reducing the number of operating workers from 12 to 4, and tripling the labor efficiency. Description of the Drawings

[0040] Figure 1 is a schematic installation diagram of the mechanical subsystem of a preferred embodiment of the automatic production system for mine drill pipes with multi-station operation of robots of the present invention;

[0041] Figure 2 is a schematic control connection diagram of the communication subsystem of a preferred embodiment of the automatic production system for mine drill pipes with multi-station operation of robots of the present invention;

[0042] Figure 3 is a flowchart of a preferred embodiment of the automatic production method for mine drill pipes with multi-station operation of robots of the present invention.

[0043] In the figure: 100 - mechanical subsystem, 200 - communication control subsystem, 300 - upstream handover area, 400 - downstream handover area, 500 - loading position, 600 - loading bench, 700 - unloading position, 800 - unloading bench;

[0044] 101-process unit, 102-robot;

[0045] 201 - information collection module, 202 - control execution module, 203 - data output and display module. DETAILED DESCRIPTION

[0046] The present invention will be further described below in conjunction with specific embodiments. It should be understood that these embodiments are only used to illustrate the present invention and are not intended to limit the scope of the present invention. In addition, it should be understood that after reading the content taught by the present invention, those skilled in the art can make various changes or modifications to the present invention, and these equivalent forms fall within the scope limited by the appended claims of the application equally.

[0047] The following takes a mining drill rod with a specification of Φ89*5.6*3000mm as an example to further illustrate this patented technology.

[0048] See also Figure 1 and Figure 2 The present invention discloses a robot multi-station operation mining drill rod automatic production system. As shown in the figure, it includes two subsystems: a mechanical subsystem 100 and a communication control subsystem 200.

[0049] See also Figure 1 , the mechanical subsystem 100 is divided into two parts: a process execution module and a robot-assisted module. The process execution module includes 11 process units 101, and the robot-assisted module includes 2 robots 102, named T1 and T2 respectively. An electric gripper is installed at the arm end of the robot 102, which can rotate 360 ​​degrees. The two robots 102 are placed side by side at different workstations, respectively located at the centers of two different circles (circle M1 and circle M2). The robot 102 located at the center of circle M1 is T1, and the robot 102 located at the center of circle M2 is T2. The two circles (circle M1 and circle M2) partially overlap, and the line connecting the two intersection points of circle M1 and circle M2 is the working boundary of the two robots. In the overlapping area, an upward transfer area 300 and a downward transfer area 400 are respectively arranged for transferring and handing over the pipe materials in process between the two robots 102: the upward transfer area 300 is used for the handover from the T1 robot 102 to the T2 robot 102, and the downward transfer area 400 is used for the handover from the T2 robot 102 to the T1 robot 102. A loading position 500, a loading platform 600, a unloading position 700 and an unloading platform 800 are arranged on one side of the circle M1.

[0050] The 11 process units 101 are divided into two categories: a processing unit and a testing unit. The processing unit is composed of a radial module and a processing device, and the testing unit is composed of a radial module and a testing device.

[0051] There are a total of 9 processing units, namely: pipe end face processing unit, friction welding unit, weld quenching unit, first weld tempering unit, second weld cooling unit, weld cooling unit, first weld turning unit, second weld turning unit, and weld grinding unit.

[0052] The pipe end face processing unit consists of a pipe threading lathe and a radial module L1, corresponding to station 1.

[0053] The friction welding unit consists of a friction welding machine and a radial module L2, corresponding to station 2.

[0054] The weld quenching unit consists of an intermediate frequency induction heating furnace, a spray quenching ring, and a radial module L3, corresponding to station 3.

[0055] The first weld tempering unit consists of an intermediate frequency induction heating furnace and a radial module L4, corresponding to station 4.

[0056] The second weld tempering unit consists of an intermediate frequency induction heating furnace and a radial module L5, corresponding to station 5.

[0057] The weld cooling unit consists of a fan, a spray device, and a radial module L6, corresponding to station 6.

[0058] The first weld turning unit consists of a pipe threading lathe and a radial module L7, corresponding to station 7.

[0059] The second weld turning unit consists of a pipe threading lathe and a radial module L8, corresponding to station 8.

[0060] The weld grinding unit consists of a grinding machine and a radial module L9, corresponding to station 9.

[0061] There are a total of 2 testing units, namely: pressure test unit and magnetic particle flaw detection unit.

[0062] The pressure test unit consists of a three-point bending testing machine, a hydraulic system, and a radial module L10, corresponding to station 10.

[0063] The magnetic particle flaw detection unit consists of a magnetic particle flaw detection device and a radial module L11, corresponding to station 11.

[0064] The radial module consists of a bench, a roller set, a ball screw pair, a baffle, a servo motor, a variable-frequency motor, and a pneumatic chuck. The servo motor, the roller set, and the ball screw pair are fixed on the bench. At one end of the ball screw pair, there are a baffle, a variable-frequency motor, and a pneumatic chuck. The entire ball screw pair is driven by the servo motor to drive the baffle, the variable-frequency motor, and the pneumatic chuck to move along the direction of the ball screw pair. During operation, after the pipe material is placed on the radial module by the electric gripper of the robot 102, it is jointly supported by the roller set arranged on one side of the ball screw pair and the baffle on the ball screw pair. Then, the pneumatic chuck acts to clamp the pipe material. The servo motor acts to drive the clamped pipe material to move along the direction of the ball screw pair to the corresponding processing equipment or testing equipment. According to the needs of processing or testing, the variable-frequency motor acts to continuously rotate the pipe material or rotate it to a specific position. After the pipe material is processed or inspected at this station, the pneumatic chuck clamps the pipe material again and, under the drive of the servo motor, brings the pipe material back to the electric gripper of the robot 102 and hands it back to the robot 102 for processing.

[0065] The installation method of the mechanical subsystem is as follows:

[0066] The production line site design: The length is 30 meters and the width is 24 meters.

[0067] The partially overlapping double-circle layout design: The distance between the centers of the circles M1 and M2 is 3.5 meters, and the radii of M1 and M2 are both 5.4 meters.

[0068] The 11 process units 101 correspond to the 11 stations in the drill pipe production process in sequence and are distributed around the circles M1 and M2 in sequence. There are 4 stations, a loading position, and an unloading position arranged outside the circle M1. The 4 stations in the counterclockwise direction are: Station 1 (pipe end turning), Station 2 (friction welding), Station 10 (weld pressure test), Station 11 (magnetic particle flaw detection). The pipe thread lathe, friction welding machine, three-point bending testing machine, and magnetic particle flaw detection equipment in the process units 101 at Station 1, Station 2, Station 10, and Station 11 are installed outside the circle M1 in sequence and are circularly distributed. And their corresponding 4 groups of radial modules are radially distributed with the center of the circle M1 as the center, and the outside of each module corresponds to the corresponding processing equipment or testing equipment respectively. Specifically, the included angle between the module at the loading position and the module at Station 1 and between the module at Station 1 and the module at Station 2 is 45 degrees, the included angle between the module at Station 10 and the module at Station 11 is 30 degrees, and the included angle between the module at Station 11 and the unloading position is 60 degrees. The modules at Station 2, the modules at Station 3, and the upward transfer area are parallel to each other, and the modules at Station 9, the modules at Station 10, and the downward transfer area are parallel to each other.

[0069] There are 7 stations arranged around the circle M12, which are counterclockwise: station 3 (weld quenching), station 4 (weld tempering), station 5 (weld tempering), station 6 (weld cooling), station 7 (weld turning), station 8 (weld turning), station 9 (weld grinding). The medium frequency induction heating furnace, spray quenching equipment, medium frequency induction heating furnace (two units), cooling fan and spray device, pipe thread lathe (two units) and grinding machine in the process unit 101 on stations 3, 4, 5, 6, 7, 8 and 9 are installed on the outside of the circle M2 in sequence and are distributed in a circular shape. The 7 groups of radial modules corresponding to them are radially distributed with the center of the circle M2 as the center, and the angle between two adjacent modules is 30 degrees. The outside of each module corresponds to the corresponding processing equipment or testing equipment.

[0070] The robot 102 is responsible for transferring the pipe material from the loading position 500 to different process units 101 until the processing is completed at the unloading position 700. At the location where two robots 102 are connected, the pipe material is transferred between the robots 102 using the upward transfer area 300 and the downward transfer area 400. The multiple groups of process units 101 that complete the pipe material transfer by the same robot 102 are arranged on a circle with the robot 102 as the center.

[0071] See also Figure 1 and Figure 2 The communication control subsystem 200 includes an information collection module 201, a control execution module 202 and a data output and display module 203, which are used to control the robot 202 to transfer the pipe material from the loading area 500 to each process unit 101 in sequence, and finally obtain the finished product in the unloading area 700. The process unit 101 is also under the control of the communication control subsystem 200, the processing unit is responsible for processing the pipe material, and the detection unit is responsible for detecting the pipe material.

[0072] The information collection module 201 includes photoelectric sensors and communication lines, and is used to collect the status of the process unit 101 and the robot 102. The information collection module 201 includes a total of 15 photoelectric sensors, which are respectively arranged on the radial modules L1 to L11, as well as the upper material position 500, the lower material position 700, the upper transfer area 300 and the lower transfer area 400. These 15 photoelectric sensors are respectively connected to the control execution module 202 through communication cables, and the collected position parameter information is transmitted to the control execution module 202 through the communication line for calculation and analysis.

[0073] At the position of the radial module, the photoelectric sensor senses the position of the pipe material on the corresponding radial module. When the pipe material is in place, the sensor is triggered and sends a pipe material in-place signal to the programmable logic controller in the control execution module 202. Specifically, when the pipe material is placed on the radial module by the robot, the sensor is triggered for the first time. The sensor sends an odd signal to the control execution module 202 through the encoder. That is, the odd signal is the pipe material in-place signal, and process machining or inspection tests need to be carried out. After the pipe material completes the process machining or inspection tests and returns to its original position, the sensor is triggered for the second time. The sensor sends an even signal to the communication control subsystem through the encoder. That is, the even signal represents that the pipe material has completed the machining at this station and can be transferred to the next station. It is the in-place signal before transfer.

[0074] At the loading position 500, the upward transfer area 300, the downward transfer area 400, and the unloading position 700 of the pipe material, only handover and transfer are carried out, and no process machining is performed. Therefore, the signals sent by the sensors located in these areas are only in-place signals.

[0075] The control execution module 202 includes a programmable logic controller, a memory, an input / output sub-module, and a power supply. The programmable logic controller uses the memory to calculate and analyze the data information of the position information from the photoelectric sensor according to the set program. While presenting the results to the staff through the input / output sub-module, it sends action execution instructions to the robot 102 and the process unit 101. The power supply provides power support for the programmable logic controller, the memory, and the input / output sub-module.

[0076] The data output and display module 203 includes a monitoring terminal, an alarm, and a data memory, and is connected to the control execution module 202. The data output and display module 203 transmits the process data collected, calculated, and analyzed to the monitoring terminal, the alarm, and the data storage in real time through the communication line, and records or displays the results in real time. For important information, the data output and display module 203 also triggers the alarm to act. The data memory is used to save the analysis and calculation results from the control execution module 202.

[0077] The specific installation and connection method of the communication control subsystem is as follows: 15 photoelectric sensors (for monitoring positions) are respectively installed on 11 radial modules, and there are also the loading position 500, the unloading position 700, the upward transfer area 300, and the downward transfer area 400. The 15 position sensors are respectively connected to the control execution module 202 through communication cables.

[0078] Meanwhile, the control execution module 202 is respectively connected to 11 radial modules through communication cables, and is used to control the servo motors, frequency conversion motors, and starting chucks in the radial modules. The control execution module 202 is respectively connected to the robots 102 (T1 and T2) through communication cables to control the rotation, lifting, pipe grasping, and pipe releasing of the robots 102. The control execution module 202 is respectively connected to the pipe threading lathe, friction welding machine, intermediate frequency quenching furnace, intermediate frequency tempering furnace, air cooling equipment, grinding machine, bending testing machine, and magnetic particle flaw detector through communication cables to control the start and stop of these processing or testing equipment.

[0079] In this system, the cooperation mode between the mechanical subsystem 100 and the communication control subsystem 200 is as shown in the system operation and process control description table.

[0080]

[0081]

[0082] In this system, the specific equipment and instrument models are as shown in the main equipment and instrument configuration table of the production line:

[0083]

[0084]

[0085] Please refer to Figure 3 , the present invention also includes a method for producing a mine drill pipe by using the above-mentioned automatic production system for multi-station operation of a robot. In a preferred embodiment thereof, the method includes the steps:

[0086] Step S1, initialize the mechanical subsystem and the communication control subsystem, and set the operation rhythm and idle signal of each process unit.

[0087] Start the system, set the operation rhythm of each process unit, and each process unit, robot, process unit, and communication control subsystem enter the waiting state for operation.

[0088] Step S2, use the feeding mechanism to move the pipe material to the feeding area, and the feeding area sends a completion signal.

[0089] The feeding mechanism starts feeding, and the first pipe material enters the feeding position, and the corresponding sensor sends an in-position signal to the communication control subsystem.

[0090] Step S3, after the communication control subsystem detects the completion signal of the feeding area, enter Step S4, otherwise continue to wait.

[0091] Step S4, when the process unit of the next process sends an idle signal, the dispatching robot transfers the pipe material to the process unit of the next process.

[0092] Based on the received signal, the communication control subsystem discovers that the robot issues an instruction under the conditions of "unit idle + loading position pipe in place + station 1 in normal state" for the next process. The robot starts and transfers the pipe from the loading position to the process unit on station 1 by grasping the pipe, moving it, and placing it. The sensor set on the station sends a signal indicating that the pipe has arrived to the communication control subsystem.

[0093] Step S5: After the communication control subsystem detects that the pipe has been placed in the process unit, it schedules the process unit to process or inspect the pipe. When the process unit completes the processing or inspection, it sends a completion signal to the communication control subsystem.

[0094] Taking station 1 as an example, after receiving the arrival signal, the communication control subsystem issues an instruction to process unit 1. The pneumatic chuck on the radial module in process unit 1 clamps one end of the pipe. The servo motor rotates, pushing the pipe forward to the position to be processed at station 1. The processing equipment (pipe threading lathe) on the station starts the turning process for the pipe end. After the processing is completed, the servo motor rotates, dragging the pipe that has completed the end turning back. The sensor set on station 1 sends an in-place signal to the communication control subsystem.

[0095] Taking station 2 as an example, the communication control subsystem issues an instruction to process unit 2. The pneumatic chuck on the radial module in process unit 2 clamps one end of the pipe. The servo motor rotates, pushing the pipe forward to the position to be processed at station 2. The processing equipment (friction welding machine) at station 2 starts working to complete the welding of the pipe and the joint. Subsequently, after dragging back the processed pipe, the sensor set on station 2 sends an in-place signal to the communication control subsystem.

[0096] Step S6: The communication control subsystem detects the completion signal of the pipe on the process unit. If the next process is a process unit, it jumps to step S4. If the next process is the upper transfer area or the lower transfer area, it enters step S7. If the next process is the unloading area, then after the unloading area sends an idle signal, the communication control subsystem schedules the robot to transfer the pipe to the unloading area to complete the processing of the pipe.

[0097] Taking the handover between station 1 and station 2 as an example, the communication control subsystem receives the in-place signal sent by the sensor at station 1 and discovers that "process unit 1 in place + process unit 2 vacant + station 2 in normal state". The communication control subsystem issues an instruction to the robot. The robot starts and transfers the pipe from station 1 to station 2 by grasping the pipe, moving it, and placing it. The sensor on station 2 sends a signal indicating that the pipe has arrived to the communication control subsystem.

[0098] Meanwhile, since the pipe material has been transferred and Station 1 is vacant, the sensor on Station 1 sends an idle signal to the communication control subsystem. Then, after the robot transfers the pipe material from Station 1 to Station 2, the communication control subsystem detects that "Station 1 is vacant + the pipe material is in place at the loading position + the status of Station 1 is normal", and thus sends an instruction to the robot. The robot starts and transfers the pipe material from the loading position to Station 1 by grasping the pipe, moving, and placing the pipe.

[0099] Step S7, after the upstream transfer area or the downstream transfer area sends an idle signal, the communication control subsystem schedules the previous robot to transfer the pipe material to the upstream transfer area or the downstream transfer area.

[0100] Taking Station 2 and the upstream transfer area as an example, when the communication control subsystem receives the in-place signal sent by the sensor on Station 2 and detects that "Station 2 is in place + the upstream transfer area is vacant", it sends an instruction to the previous robot. The robot starts and transfers the pipe material from Station 2 to the upstream transfer area by grasping the pipe, moving, and placing the pipe. At this time, the sensor located in the upstream transfer area sends a pipe material in-place signal to the communication control subsystem.

[0101] Step S8, after the pipe material is in place in the upstream transfer area or the downstream transfer area, the upstream transfer area or the downstream transfer area sends a completion signal, and jumps to Step S4.

[0102] Taking the upstream transfer area and Station 3 as an example, when the communication control subsystem detects that "the pipe material is in place in the upstream transfer area + Station 3 is vacant + the status of Station 3 is normal", it sends an instruction to the subsequent robot. The subsequent robot starts and transfers the pipe material from the upstream transfer area to Station 3 by grasping the pipe, moving, and placing the pipe. The sensor located on Station 3 sends a pipe material in-place signal to the communication control subsystem. Then, the upstream transfer area becomes vacant.

[0103] The communication control subsystem makes a logical judgment according to the logic of "Station (n) is in place + Module (n + 1) is vacant + the status of Station (n + 1) is normal", and commands two robots to start from the loading area with the pipe material, and successively pass through 11 stations including weld quenching, weld tempering (the first time), upstream transfer area, weld tempering (the second time), weld cooling, weld turning 1, weld turning 2, weld outer surface grinding, downstream transfer area, weld bending test, and weld and surrounding magnetic particle inspection, and reach the unloading area to complete the processing of one end of the pipe material. Then, at the unloading position (or loading position), a 180-degree turn is completed to turn the end with the joint outward. Then, the above steps are executed again to complete the end face turning, joint welding, weld quenching, weld tempering (twice), weld cooling, weld turning 1, weld turning 2, weld outer surface grinding, weld bending test, and weld and surrounding magnetic particle inspection of the other end of the pipe material. In actual production, the production line runs continuously, and after these steps, the automated production of a mining drill pipe is completed.

[0104] Taking the mine drill pipe with the specification of Φ89*5.6*3000mm as an example, after 120 minutes of operation, the system can complete the production of 30 drill pipes. The production efficiency is 15 pieces per hour.

[0105] In the above production process, the specific beat settings are shown in the production beat setting table:

[0106] Station Process Content Time (min) Station 1 Tube End Turning Process ≤2.5 Station 2 Friction Welding ≤2.5 Station 3 Weld Quenching ≤2 Station 4 Weld Tempering (First Time) ≤2.5 Station 5 Weld Tempering (Second Time) ≤2.5 Station 6 Weld Cooling ≤1 Station 7 Weld Flash Turning ≤1 Station 8 Weld Flash Turning ≤1 Station 9 Weld Grinding ≤2 Station 10 Weld Bending Test ≤2 Station 11 Magnetic Particle Inspection of Weld and Surroundings ≤1.5 Module Advancing and Retreating ≤2 Robot Operation ≤2.5 Maximum Single-Station Operation Time (Friction Welding) ≤2.5

[0107] The above are only the preferred embodiments of the present invention, and do not limit the patent scope of the present invention. Any equivalent structure or equivalent process transformation made by using the content of the specification and drawings of the present invention, or directly or indirectly applied in other related technical fields, shall be equally included in the patent protection scope of the present invention.

Claims

1. An automated production system for mine drill pipes with multi-station operation of robots, characterized in that, It includes a mechanical subsystem and a communication control subsystem; The mechanical subsystem includes multiple groups of process units and multiple robots; the robots transfer the pipe materials among different process units, and the process units process or detect the pipe materials; Multiple groups of process units that are transferred by the same robot are arranged on a circle centered on the robot; when there are multiple robots, the circular parts corresponding to different robots overlap to form an overlapping area; in the overlapping area, an upward transfer area and a downward transfer area are set up for transferring and handing over the pipe materials between two robots; The process unit includes a radial module and a processing device or a detection device; the radial module transfers the pipe material delivered by the robot to the processing device for processing, or transfers the pipe material to the detection device for detection; after the processing or detection is completed, the radial module transfers the pipe material back to the robot for the robot to handle; The communication control subsystem controls the robot to start from the loading area, transfer the pipe material to each process unit in turn, and finally obtain the finished product at the unloading area; Under the control of the communication control subsystem, the process unit processes or detects the pipe material; The communication control subsystem includes an information acquisition module, a control execution module, and a data output and display module; the information acquisition module is an optoelectronic sensor; the optoelectronic sensor is arranged at each process unit and the robot for acquiring the status information of the process unit and the robot; At the position of the radial module, the optoelectronic sensor senses the position of the pipe material on the radial module where it is located; when the pipe material is placed on the radial module by the robot, the sensor is triggered for the first time, and the sensor sends an odd signal to the control execution module, that is, the odd signal is the pipe material in-place signal, and process processing or detection test is required; after the pipe material completes the process processing or detection test and returns to the original position, the sensor is triggered for the second time, and the sensor sends an even signal to the communication control subsystem, that is, the even signal represents that the pipe material has completed the processing at this station and can be transferred to the next station, and it is the in-place signal before transfer; when the pipe material is at the loading position, the upward transfer area, the downward transfer area, and the unloading position, only handover and transfer are carried out, and no process processing is performed, so the signals sent by the sensors located in these areas are only in-place signals.

2. The automated production system for mine drill pipes with multi-station operation of robots according to claim 1, characterized in that, The processing devices are pipe thread lathes, friction welding machines, intermediate frequency induction heating furnaces, spray quenching rings, fans, spray devices, and grinding machines.

3. The automated production system for mine drill pipes with multi-station operation of robots according to claim 2, characterized in that, The pipe thread lathe and the radial module form a pipe body end face processing unit or a weld turning unit; the friction welding machine and the radial module form a friction welding unit; the intermediate frequency induction heating furnace, the spray quenching ring, and the radial module form a weld quenching unit; the intermediate frequency induction heating furnace and the radial module form a weld tempering unit; the fan, the spray device, and the radial module form a weld cooling unit; the grinding machine and the radial module form a weld grinding unit.

4. The automated production system for mine drill pipes with multi-station operation of robots according to claim 1, characterized in that, The detection devices include a three-point bending testing machine, a hydraulic system, and a magnetic particle flaw detection device.

5. The automated production system for mine drill pipes with multi-station operation of robots according to claim 4, characterized in that, The three-point bending testing machine, the hydraulic system, and the radial module constitute a pressure testing unit; the magnetic particle flaw detection equipment and the radial module constitute a magnetic particle flaw detection unit.

6. The automated production system for mine drill pipes with multi-station operation of robots according to claim 1, characterized in that, The radial module is composed of a bench, a roller set, a ball screw pair, a baffle, a servo motor, a variable-frequency motor, and a pneumatic chuck; the servo motor, the roller set, and the ball screw pair are fixed on the bench; the baffle, the variable-frequency motor, and the pneumatic chuck are fixed on the ball screw pair and move along the direction of the ball screw pair driven by the servo motor; the pipe material placed by the robot is supported by the roller set and the baffle on the ball screw pair; The pneumatic chuck clamps the pipe material, the variable-frequency motor drives the pipe material to rotate, and the servo motor drives the pipe material to transfer.

7. The automated production system for mine drill pipes with multi-station operation of robots according to claim 1, characterized in that, The information acquisition module collects the states of the process unit and the robot and transmits them to the control execution module for calculation and analysis; the control execution module issues control instructions to the process unit or the robot according to the results of the calculation and analysis; the data output and display module is connected to the control execution module to record or display the results of the calculation and analysis of the control execution module in real time.

8. The automated production system for mine drill pipes with multi-station operation of robots according to claim 7, characterized in that, The control execution module includes a programmable controller, a memory, an input / output sub-module, and a power supply; the programmable controller uses the memory to calculate and analyze the information from the information acquisition module and displays the results through the input / output sub-module; The power supply provides power support for the programmable controller, the memory, and the input / output sub-module.

9. The automated production system for mine drill pipes with multi-station operation of robots according to claim 7, characterized in that, The data output and display module includes a monitoring terminal, an alarm, and a data memory; The control execution module transmits the analysis and calculation results to the monitoring terminal and triggers the alarm to act according to the analysis and calculation results; the data memory is used to save the analysis and calculation results from the control execution module.

10. A method for producing mine drill pipes using the automated production system for mine drill pipes with multi-station operation of robots as claimed in claim 1, characterized in that, Including steps: Step S101, initialize the mechanical subsystem and the communication control subsystem, and set the operation rhythm and idle signal of each process unit; Step S102, use the feeding mechanism to move the pipe material to the feeding area, and the feeding area issues a completion signal; Step S103, after the communication control subsystem detects the completion signal of the feeding area, enter Step S104, otherwise continue to wait; Step S104, when the process unit of the next process issues an idle signal, dispatch the robot to transfer the pipe material to the process unit of the next process; Step S105, after the communication control subsystem detects that the pipe material is in place in the process unit, dispatch the process unit to process or detect the pipe material; after the process unit completes the processing or detection, send a completion signal to the communication control subsystem; Step S106: The communication control subsystem detects the completion signal of the pipe material on the process unit. If the next process is the process unit, jump to step S104; if the next process is the blanking area, after the blanking area sends an idle signal, the communication control subsystem schedules the robot to transfer the pipe material to the blanking area to complete the processing of the pipe material.

11. A method for producing mine drill pipes using an automated production system for mine drill pipes with multi-station operation of a robot as described in claim 1, characterized in that, Including steps: Step S201: Initialize the mechanical subsystem and the communication control subsystem, and set the operation rhythm and idle signal of each process unit. Step S202: Use the loading mechanism to move the pipe material to the loading area, and the loading area sends a completion signal. Step S203: After the communication control subsystem detects the completion signal of the loading area, enter step S204; otherwise, continue to wait. Step S204: When the process unit of the next process sends an idle signal, schedule the robot to transfer the pipe material to the process unit of the next process. Step S205: After the communication control subsystem detects that the pipe material is in place on the process unit, schedule the process unit to process or detect the pipe material; when the process unit completes the processing or detection, send a completion signal to the communication control subsystem. Step S206: The communication control subsystem detects the completion signal of the pipe material on the process unit. If the next process is the process unit, jump to step S204; if the next process is the upstream transfer area or the downstream transfer area, enter step S207; if the next process is the blanking area, after the blanking area sends an idle signal, the communication control subsystem schedules the robot to transfer the pipe material to the blanking area to complete the processing of the pipe material. Step S207: After the upstream transfer area or the downstream transfer area sends an idle signal, the communication control subsystem schedules the previous robot to transfer the pipe material to the upstream transfer area or the downstream transfer area and hand it over to the subsequent robot. Step S208: When the pipe material is in place in the upstream transfer area or the downstream transfer area, the upstream transfer area or the downstream transfer area sends a completion signal and jumps to step S204.

12. The method for producing mine drill pipes according to claim 10 or 11, characterized in that, The pipe material forms the finished product from the loading area to the blanking area, and the process units passed through are in sequence: pipe body end face processing unit, friction welding unit, weld quenching unit, first weld tempering unit, second weld tempering unit, weld cooling unit, first weld turning unit, second weld turning unit and weld grinding unit, pressure test unit and magnetic particle flaw detection unit.

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