Method for straightening a sheet metal part, straightening device and machine-readable storage medium

Abstract

The application discloses a plate deformation flattening method, a flattening device and a machine readable storage medium, the method comprising the following steps: initially measuring the workpiece flatness of a workpiece to be flattened and judging whether it is qualified or not; in the case that the workpiece flatness is unqualified, determining an out-of-tolerance point and an initial deformation amount of the out-of-tolerance point; according to the initial deformation amount of the out-of-tolerance point, calculating a workpiece flattening counter-deformation amount of the out-of-tolerance point; controlling a pressure head to align with the out-of-tolerance point and to move towards the workpiece to be flattened after contacting the out-of-tolerance point to apply pressure until the pressure stroke reaches the workpiece flattening counter-deformation amount, and then controlling the pressure head to retreat, thus completing one flattening operation. Through the steps of automatic workpiece positioning, automatic workpiece flatness detection and judgment, workpiece flattening counter-deformation amount calculation, accurate correction pressure stroke of the flattening pressure head, and workpiece flatness re-measurement after flattening, the application can realize automatic hydraulic flattening of a medium-thick plate, replace manual flattening, has high efficiency and stable quality.

Description

Technical Field

[0001] This invention belongs to the field of processing technology, specifically relating to a method for leveling deformed plates, a leveling device, and a machine-readable storage medium. Background Technology

[0002] In engineering machinery, medium-thickness high-strength steel plates are often used in many structural components to withstand large loads. To save on raw material costs, reinforced medium-thickness plates are frequently used in welded assemblies. However, uneven stress distribution during welding can easily lead to deformation of the welded components. Deformation of the welded assembly affects the assembly accuracy and machining allowance of subsequent welded structural parts. Therefore, how to straighten these components is a crucial issue to address in the production of welded structural parts. Thus, leveling measures are needed to control the deformation within the required range.

[0003] Currently, the main methods for leveling medium and heavy plates are flame straightening and mechanical straightening. Flame straightening utilizes the thermal expansion and contraction properties of metal materials. When a localized area is heated, the material's thermal expansion is hindered. When the compressive force exceeds the yield limit, compressive plastic deformation occurs. After heating stops, the metal cools and contracts, and the contraction exceeds the expansion, thus creating a new deformation. Flame straightening uses this new deformation produced by localized heating to correct the original deformation. Mechanical straightening methods include pressure straightening and roller straightening. The working principle of a pressure straightening machine is to support the workpiece with its original bend between two movable fulcrums on a worktable and use a pressure head to reverse the bending. This is the simplest and most effective straightening method. The parallel roller straightening method of a roller straightening machine transforms the intermittent pressure straightening method into a continuous roller straightening method. Several parallel straightening rollers are arranged alternately from the inlet to the outlet, repeatedly bending according to a decreasing pressure bending pattern to achieve the straightening purpose.

[0004] However, flame straightening places high demands on both skilled workers and operators, resulting in inconsistent straightening effects and low production efficiency. Selecting the appropriate heating point during flame straightening is challenging; improper selection can lead to new deformations instead of correcting the original ones. Even with accurate heating point selection, poor flame temperature control can cause other problems, such as phase transformation and softening due to excessively high temperatures. Furthermore, repeated flame straightening can degrade material properties. Roller straightening machines are suitable for mass production of sheet metal. However, for leveling thick plates, roller straightening machines are too expensive, require a large area, and are unsuitable for leveling welded structural components. Pressure straightening is often performed manually, relying on the operator's feel and experience, resulting in low efficiency, inconsistent quality, and high labor intensity, failing to meet the high-quality, high-efficiency, and rapid production requirements of modern enterprises. Summary of the Invention

[0005] To address the aforementioned deficiencies or shortcomings, this invention provides a method, apparatus, and machine-readable storage medium for leveling deformed sheet metal, thereby achieving efficient and high-precision automated leveling operations.

[0006] According to a first aspect of the present invention, a method for straightening deformation of a plate is provided, comprising:

[0007] Initially measure the flatness of the workpiece to be leveled and determine whether it is qualified;

[0008] In the case where the flatness of the workpiece is unqualified, determine the out-of-tolerance point and the initial deformation amount of the out-of-tolerance point;

[0009] Based on the initial deformation amount of the out-of-tolerance point, calculate the workpiece leveling reverse deformation amount of the out-of-tolerance point;

[0010] The pressure head is aligned with the deviation point, and after contacting the deviation point, it moves towards the workpiece to be leveled and applies pressure until the corrective pressure stroke of the pressure head reaches the leveling and anti-deformation of the workpiece. Then, the pressure head is controlled to retract, completing one leveling operation.

[0011] In some embodiments, the workpiece leveling deformation amount at the excess point satisfies:

[0012] l=k·t·σ s +F;

[0013] Where l is the amount of reverse deformation during leveling of the workpiece at the point of excess error, t is the plate thickness of the workpiece to be leveled, and σ s Let be the yield strength of the workpiece to be leveled, k be the material coefficient, and F be the initial deformation of the deviation point.

[0014] In some embodiments, the step of initially measuring the flatness of the workpiece to be leveled and determining whether it is qualified includes:

[0015] The actual height A at the detection point on the surface of the workpiece to be leveled was measured. i And using the height of the workpiece surface to be leveled as the reference height A0, the initial deformation F at the detection point is obtained. i =A0-A i ;

[0016] The maximum absolute value of the initial deformation at each detection point on the workpiece surface is compared with the set flatness standard value to determine whether the workpiece flatness is qualified.

[0017] In some embodiments, when the workpiece flatness is unacceptable, the step of determining the out-of-tolerance point and the initial deformation amount of the out-of-tolerance point includes:

[0018] The initial deformation F at the detection point i If the absolute value of the error is greater than the set out-of-tolerance standard value, the detection point is determined to be the out-of-tolerance point.

[0019] In some embodiments, the method further includes:

[0020] Before controlling the pressure head to align with the out-of-tolerance point and move towards the workpiece to be leveled to apply pressure, the leveling direction of the out-of-tolerance point is determined according to the initial deformation type of the out-of-tolerance point;

[0021] In response to the determined leveling direction, the corresponding leveling fixture that is used in conjunction with the pressure head is retrieved.

[0022] In some embodiments, before controlling the pressure head to align with the deviation point and move towards the workpiece to be leveled to apply pressure, the step of determining the leveling direction of the deviation point based on the initial deformation type of the deviation point further includes:

[0023] The actual height at the point of deviation and the reference height based on the height of the workpiece surface of the workpiece to be leveled are measured.

[0024] The initial deformation type of the out-of-tolerance point is determined by comparing the actual height with the reference height.

[0025] In some embodiments, the workpiece to be leveled is a circular welded structure and includes:

[0026] round plate; and

[0027] A circular ring plate is welded to the surface of the circular plate. An outer ring fillet weld is formed between the outer edge of the circular ring plate and the surface of the circular plate, and an inner ring fillet weld is formed between the inner edge of the circular ring plate and the surface of the circular plate.

[0028] The method further includes:

[0029] Before the initial measurement of the flatness of the workpiece to be leveled and the determination of whether it is qualified, the workpiece to be leveled is moved to the tooling platform and positioned.

[0030] After determining that the flatness of the workpiece to be leveled is unqualified, the point of excess deviation is rotated to the leveling position on the tooling platform.

[0031] In some embodiments, the workpiece to be leveled is a medium-thick plate of 30-80mm.

[0032] In some embodiments, the method further includes:

[0033] After completing one leveling operation, the flatness of the workpiece to be leveled is re-measured, and if the flatness of the re-measured workpiece is still unqualified, the next leveling operation is repeated.

[0034] According to a second aspect of the present invention, a leveling device is provided, comprising:

[0035] Leveling fixtures are used to support and position the workpiece to be leveled;

[0036] A leveling and pressure-applying mechanism, spaced apart from the leveling fixture and including a pressure head extending toward the leveling fixture;

[0037] Displacement sensor, used to detect the position of the pressure head;

[0038] Flatness measuring instrument; and

[0039] The controller is configured as follows:

[0040] Control the flatness testing instrument to initially measure the flatness of the workpiece to be leveled;

[0041] The workpiece is determined to be non-compliant in terms of flatness, and the point of deviation and the initial deformation of the point of deviation are identified.

[0042] Based on the initial deformation amount of the out-of-tolerance point, calculate the workpiece leveling reverse deformation amount of the out-of-tolerance point and determine the pressure head stop position;

[0043] Control the leveling and pressure application mechanism to drive the pressure head to align and contact the out-of-tolerance point, and then move it toward the workpiece to be leveled to apply pressure.

[0044] Using the displacement sensor, the pressure head is controlled to stop and retract after reaching the amount of workpiece leveling and anti-deformation, thus completing one leveling operation.

[0045] In some embodiments, the workpiece leveling deformation amount at the excess point satisfies:

[0046] l=k·t·σ s +F;

[0047] Where l is the amount of reverse deformation during leveling of the workpiece at the point of excess error, t is the plate thickness of the workpiece to be leveled, and σ s Let be the yield strength of the workpiece to be leveled, k be the material coefficient, and F be the initial deformation of the point of deviation.

[0048] In some implementations, determining that the workpiece flatness is unqualified and identifying the deviation point and the initial deformation of the deviation point includes:

[0049] The actual height A at the detection point on the surface of the workpiece to be leveled was measured. iAnd using the height of the workpiece surface to be leveled as the reference height A0, the initial deformation F at the detection point is obtained. i =A0-A i ;

[0050] If the absolute value of the initial deformation at each detection point on the surface of the workpiece is greater than the set flatness standard value, the workpiece flatness is deemed unqualified.

[0051] Determine the initial deformation F at the detection point. i If the absolute value of the error is greater than the set out-of-tolerance standard value, the detection point is determined to be the out-of-tolerance point.

[0052] In some implementations, the controller is further configured to:

[0053] Before controlling the leveling and pressing mechanism to drive the pressure head to align with the out-of-tolerance point and move towards the workpiece to be leveled to apply pressure, the leveling direction of the out-of-tolerance point is determined according to the initial deformation type of the out-of-tolerance point.

[0054] In response to the determined leveling direction, the corresponding leveling fixture that is used in conjunction with the pressure head is retrieved.

[0055] In some embodiments, before controlling the leveling and pressing mechanism to drive the pressure head to align with the deviation point and move towards the workpiece to be leveled to apply pressure, determining the leveling direction of the deviation point based on the initial deformation type of the deviation point includes:

[0056] Control the flatness testing instrument to measure the actual height at the point of deviation and the reference height based on the height of the workpiece surface of the workpiece to be leveled;

[0057] The initial deformation type of the out-of-tolerance point is determined by comparing the actual height with the reference height.

[0058] In some embodiments, the leveling fixture includes:

[0059] An upward-convex leveling assembly is used to level the concave deformation of a workpiece to be leveled. The assembly includes a top support boss supporting the workpiece from below and a pressure-applying bracket positioned above the workpiece to receive leveling pressure. The bottom of the pressure-applying bracket has multiple horizontally spaced and downwardly extending abutting ends. The top support boss is positioned below the pressure-applying bracket and located in the horizontally spaced space between adjacent abutting ends.

[0060] A concave leveling assembly is used to level the upward convex deformation of the workpiece to be leveled. The concave leveling assembly is arranged below the workpiece to be leveled and includes a plurality of leveling supports arranged laterally at intervals.

[0061] Furthermore, the process of retrieving the leveling direction determined by the judgment, and retrieving the corresponding leveling fixture used in conjunction with the pressure head, includes:

[0062] When the leveling direction is determined to be an upward convex deformation, the downward concave leveling component is retrieved;

[0063] When the leveling direction is determined to be a concave deformation, the convex leveling component is retrieved.

[0064] In some embodiments, the leveling fixture includes:

[0065] A tooling platform, wherein multiple sets of the aforementioned convex leveling components are arranged symmetrically about the platform center of the top platform surface; and

[0066] A lifting and rotating part is arranged on the top platform surface of the tooling platform and is used to drive the workpiece to be leveled to lift and / or rotate.

[0067] Furthermore, the workpiece to be leveled is a circular welded structure and includes:

[0068] round plate; and

[0069] A circular ring plate is welded to the surface of the circular plate. An outer ring fillet weld is formed between the outer edge of the circular ring plate and the surface of the circular plate, and an inner ring fillet weld is formed between the inner edge of the circular ring plate and the surface of the circular plate.

[0070] Furthermore, the control of the flatness testing instrument to initially measure the flatness of the workpiece to be leveled includes:

[0071] Move the workpiece to be leveled onto the tooling platform;

[0072] Move the flatness measuring instrument directly above the annular plate;

[0073] The lifting and rotating part is controlled to lift and rotate the workpiece to be leveled, so as to cooperate with the flatness measuring instrument to initially measure the flatness of the workpiece;

[0074] Furthermore, the step of determining that the flatness of the workpiece is unqualified and identifying the out-of-tolerance point and the initial deformation amount of the out-of-tolerance point also includes:

[0075] After determining the deviation point, the lifting and rotating part is controlled to lift and rotate the workpiece to be leveled, so that the deviation point moves to the leveling position.

[0076] In some embodiments, the leveling device includes:

[0077] A centering mechanism is used to center and position the workpiece to be leveled, and the centering mechanism is arranged on the outer periphery of the leveling fixture.

[0078] Furthermore, moving the workpiece to be leveled onto the tooling platform also includes:

[0079] Control the centering mechanism to center and position the workpiece to be leveled on the tooling platform.

[0080] In some embodiments, the leveling device further includes:

[0081] The gantry includes a crossbeam, and the leveling and pressing mechanism is capable of moving horizontally along the crossbeam to drive the pressure head and the adjacent flatness detector and displacement sensor to move horizontally.

[0082] Furthermore, controlling the leveling and pressure-applying mechanism to drive the pressure head to align with the deviation point and move towards the workpiece to be leveled to apply pressure also includes:

[0083] The leveling and pressure-applying mechanism is controlled to move horizontally along the crossbeam, thereby moving the displacement sensor, the flatness detector, and the displacement sensor to the leveling position.

[0084] In some embodiments, the leveling device further includes:

[0085] A workbench is located below the crossbeam, and the leveling fixture and the centering mechanism are arranged on the workbench;

[0086] A base, on which the worktable is detachably mounted;

[0087] The gantry includes a U-shaped main frame, the crossbeam spans the top opening of the U-shaped main frame, and the base is disposed at the bottom of the U-shaped cavity within the U-shaped main frame.

[0088] In some embodiments, the leveling and pressure-applying mechanism includes a hydraulic cylinder and a servo motor for driving the hydraulic cylinder to move horizontally along the crossbeam. Under hydraulic drive, the piston rod of the hydraulic cylinder can extend downward and push the pressure head to apply pressure to the workpiece to be leveled; and / or

[0089] The flatness testing instrument is a line laser scanner or a three-dimensional vision camera.

[0090] In some implementations, the controller is further configured to:

[0091] After completing one leveling operation, the flatness of the workpiece to be leveled is re-measured, and if the flatness of the re-measured workpiece is not up to standard, the next leveling operation is repeated.

[0092] According to a third aspect of the invention, a machine-readable storage medium is also provided, on which instructions are stored, which, when executed by a processor, enable the processor to perform the plate deformation straightening method described above according to the invention.

[0093] This invention achieves fully automated hydraulic leveling of medium and heavy plates through steps such as automatic workpiece flatness detection and judgment, calculation of workpiece leveling deformation, precise stopping position control of the pressure head during leveling, and even automatic workpiece positioning and post-leveling flatness re-measurement. This replaces manual leveling, eliminating reliance on operator feel and experience, resulting in high efficiency and stable quality. The leveling device has a small footprint, a simple structure, and low cost, meeting the high-quality, high-efficiency, and rapid production requirements of modern enterprises.

[0094] Other features and advantages of the present invention will be described in detail in the following detailed description section. Attached Figure Description

[0095] The accompanying drawings are provided to illustrate the invention and form part of the specification. They are used together with the following detailed description to explain the invention, but do not constitute a limitation thereof. In the drawings:

[0096] Figure 1 , Figure 2 These are the top view and sectional view of the annular welded structure that is the workpiece to be leveled.

[0097] Figure 3 This is a schematic diagram of the leveling device according to a specific embodiment of the present invention;

[0098] Figure 4 , Figure 5 , Figure 6 These are, respectively, the front view, top view, and side view of the leveling fixture according to a specific embodiment of the present invention;

[0099] Figure 7 This is a schematic diagram of the lifting and rotating part in the leveling fixture according to a specific embodiment of the present invention in the lifting and rotating state.

[0100] Figure 8 This is a schematic diagram of the lifting and rotating part of the leveling fixture according to a specific embodiment of the present invention in the lowered support state.

[0101] Figure 9 , Figure 10These are schematic diagrams illustrating the operation process of the leveling fixture according to specific embodiments of the present invention when correcting concave deformation and convex deformation;

[0102] Figure 11 A step diagram illustrating the plate deformation leveling method according to a specific embodiment of the present invention; and

[0103] Figure 12 This is a flowchart illustrating the operation of a plate deformation leveling method according to a specific embodiment of the present invention.

[0104] Explanation of reference numerals in the attached figures

[0105] 1. Circular plate 2. Circular ring plate

[0106] 3 Outer ring fillet weld 4 Inner ring fillet weld

[0107] 10 bases

[0108] 20 gantry, 30 worktable

[0109] 40 Leveling fixture; 50 Workpieces to be leveled

[0110] 60 centering mechanism 70 crossbeam

[0111] 80 Flatness measuring instrument, 90 Indenter

[0112] 100 hydraulic cylinder, 110 servo motor

[0113] 120 Displacement Sensor 130 Tooling Platform

[0114] 140 Leveling support component 150 Rotation mechanism

[0115] 151 Rotary Support Platform

[0116] 160 Lifting mechanism; 170 Top support boss

[0117] 180 Pressure support 181 Pressure end Detailed Implementation

[0118] The specific embodiments of the present invention will be described in detail below with reference to the accompanying drawings. It should be understood that the specific embodiments described herein are for illustration and explanation only and are not intended to limit the present invention.

[0119] The following description, with reference to the accompanying drawings, describes a plate deformation leveling method, leveling device, and machine-readable storage medium according to the present invention.

[0120] To achieve efficient and high-precision automated leveling operations, it is necessary to first explore leveling devices suitable for automated control and operation. In existing pressure-based straightening methods for medium and heavy plates, such as planar hydraulic straightening, manual operation is generally used, and the leveling direction is typically concave. When the workpiece needs to be leveled in the opposite direction, it is often achieved by flipping the workpiece, which leads to low efficiency and hinders automation. Therefore, this invention first designs a novel leveling fixture. For example... Figures 3 to 10 As shown, in one specific embodiment, the leveling fixture 40 includes:

[0121] The upper convex leveling assembly is used to correct the concave deformation of the workpiece 50 to be leveled. The upper convex leveling assembly includes a top support boss 170 that supports the workpiece 50 to be leveled from below and a pressure support 180 that is arranged above the workpiece 50 to be leveled and bears the leveling pressure. The bottom of the pressure support 180 is provided with a plurality of horizontally spaced and downwardly extending abutting ends 181. The top support boss 170 is arranged below the pressure support 180 and is located in the horizontally spaced space between adjacent abutting ends 181.

[0122] like Figure 9 As shown, the workpiece 50 to be leveled has a concave deformation at its initial position before leveling. In existing operations, the workpiece is usually manually flipped over, and then the pressure head 90 is pressed down in the center for correction. This adds flipping and alignment steps, and requires process interruption and manual intervention. However, Figure 9 In this process, after adopting the upper convex leveling component, the top support boss 170 supports the workpiece to be leveled from below. The pressure applied by the pressure head 90 acts on the pressure support 180, and then acts on the workpiece to be leveled through the pressure end 181 of the pressure support 180. As shown in the figure, the two pressure ends 181 are distributed on both sides of the lateral side of the top support boss 170. After the pressure head 90 presses down, the workpiece to be leveled will deform from the initial position before leveling to the over-pressure position before leveling, and finally spring back to the springback position after leveling, basically forming a horizontal state after leveling, thus achieving basic leveling.

[0123] Similarly, see Figure 10 The leveling tooling 40 also includes:

[0124] A concave leveling assembly is used to level the convex deformation of the workpiece 50 to be leveled. The concave leveling assembly is arranged below the workpiece 50 to be leveled and includes a plurality of leveling supports 140 arranged laterally at intervals.

[0125] As can be seen, for upward convex deformation, only multiple leveling supports 140 need to be set up and arranged around the periphery of the upward convex deformation position, and then the pressure head 90 presses down in the center, which can also level the flat part. In this way, the leveling fixture 40 can include upward convex leveling components and downward concave leveling components. The leveling component type can be provided according to the deformation type of the workpiece 50 to be leveled, thereby meeting the needs of the leveling operation. Furthermore, it can help to realize automated processes such as deformation type judgment, leveling component selection, assembly, and leveling, which will be explained in detail below.

[0126] It should be noted that, as Figure 1 , Figure 2 As shown, as an example, the workpiece 50 to be leveled in this embodiment is a circular welded structure and includes:

[0127] Circular plate 1, the center of circular plate 1 is vertically aligned with the center of the platform; and

[0128] A circular ring plate 2 is welded to the surface of a circular plate 1. An outer ring fillet weld 3 is formed between the outer edge of the circular ring plate 2 and the surface of the circular plate 1, and an inner ring fillet weld 4 is formed between the inner edge of the circular ring plate 2 and the surface of the circular plate 1.

[0129] Such annular welded structural components are commonly found in the rotating mechanisms of engineering machinery. After welding and cooling, the shrinkage deformation causes the flatness of the component to exceed tolerances, requiring leveling measures to control its flatness within the required range. Specifically, uneven deformation generally occurs on the surface of the annular plate 2; it is sufficient to ensure that the flatness of the annular plate surface meets the requirements. Of course, this is only an example, and the present invention is not limited to circular or annular metal plates; it can also be used for leveling other types of plates. Moreover, in this embodiment, the workpiece 50 to be leveled is specified as a medium-thickness plate of 30–80 mm, but it is obviously not limited to this.

[0130] like Figures 4 to 6 The leveling fixture 40 may also include:

[0131] Tooling platform 130, multiple sets of upward convex leveling components are arranged on the top platform surface of tooling platform 130 and are arranged symmetrically about the platform center of the top platform surface.

[0132] Among them, tooling platform 130 is the foundation and main support of the leveling tooling. For example... Figure 5 As shown, as an example, the tooling platform 130 is a rectangular platform. The center of the top platform surface of the tooling platform 130 can serve as the reference center for arranging other components of the leveling tooling 40. For example, multiple sets of upwardly convex leveling components can be arranged symmetrically and parallelly around the platform center, such as... Figure 5 As shown, it obviously includes two sets of concave leveling components that are symmetrical on the left and right, that is, a total of 4 leveling support components 140.

[0133] Specifically, the number of sets of the concave leveling components and the convex leveling components is the same. Each set of concave leveling components includes two leveling supports 140 spaced laterally apart, and each set of convex leveling components includes two pressing ends 181, such as... Figure 9 , Figure 10 As shown.

[0134] Leveling tooling 40 also includes:

[0135] The lifting and rotating part is arranged on the top platform surface of the tooling platform 130 and is used to drive the workpiece 50 to be leveled to lift and / or rotate.

[0136] The rotation center of the lifting and rotating part is aligned with the center of the platform, so that the workpiece 50 to be leveled can be rotated to rotate any concave or convex deformed part on the annular plate 2 to the leveling position directly below the pressure head 90.

[0137] See Figure 5 The leveling position refers to the position between the two leveling supports 140 of each set of concave leveling components. Figure 5 Two leveling positions are arranged in the middle. The lifting and rotating part can rotate and move the part to be leveled on the annular plate 2 (i.e. the part with excess error after leveling) to the leveling position. The pressure head 90 can also selectively switch and move laterally between the two leveling positions.

[0138] Specifically, as an example, the lifting and rotating part may include:

[0139] The rotating mechanism 150 includes a rotating support platform 151 for supporting the workpiece 50 to be leveled and a rotating drive mechanism for driving the rotating support platform 151 to rotate together with the workpiece 50 to be leveled; and

[0140] The lifting mechanism 160 is used to lift and drive the rotating support platform 151.

[0141] See Figure 4 As an example, the rotating mechanism 150 may consist of a rotating support platform 151, gears, a rotary motor, etc. The rotary motor can drive the rotating support platform 151 to rotate, and the lifting mechanism 160 can lift and lower the rotating support platform 151. Figure 7 As shown, the lifting and rotating part is in the lifting and rotating state, that is, the lifting mechanism 160 first lifts the rotating support platform 151 until the rotating support platform 151 contacts and supports the workpiece 50 to be leveled, so that the workpiece 50 to be leveled is lifted off the support of the leveling support 140. Then the rotating drive mechanism drives the rotating support platform 151 to rotate together with the workpiece 50 to be leveled, until the specific concave and convex deformation part on the annular plate 2 to be leveled is rotated to the leveling position directly below the pressure head 90.

[0142] like Figure 8 As shown, the lifting and rotating part is in the lowered support state. Figure 7 In the process shown, after rotating the specific uneven deformation portion on the annular plate 2 to the leveling position directly below the pressure head 90, the lifting mechanism 160 is controlled to lower the rotating support platform 151 until the workpiece 50 to be leveled is supported on the leveling support 140, ready for the subsequent leveling operation by the pressure head 90. Afterwards, the lifting mechanism 160 continues to lower the rotating support platform 151, causing the rotating support platform 151 to disengage from the workpiece 50 to be leveled. This allows for... Figure 9 or Figure 10 The leveling operation shown will not cause any mechanical interference with the lifting and rotating parts of the centrally located leveling fixture 40.

[0143] Specifically, the rotary drive mechanism can use an asynchronous motor to achieve the jogging function during manual operation. The lifting mechanism 160 can consist of 2 or 4 lifting cylinders, which raise and lower the workpiece 50 to be leveled to two states.

[0144] See Figure 4 , Figure 5 On the top platform surface of the tooling platform 130, the lifting and rotating part is centrally located, and the upper convex leveling component or the lower concave leveling component is arranged on the circumferential outer side of the lifting and rotating part. The leveling support 140 is located above the tooling platform 130, with four support points distributed on the left and right sides. During leveling, the pressure head 90 applies downward pressure above the workpiece 50 to be leveled, and the workpiece receives reverse support at the support points, thereby causing the workpiece 50 to be leveled to undergo bending deformation.

[0145] Secondly, the present invention also designs a novel leveling device, including the aforementioned leveling fixture 40. For example... Figure 3 As shown, in one specific embodiment, the leveling device includes:

[0146] Leveling tooling 40; and

[0147] The leveling and pressure-applying mechanism is arranged at intervals above the leveling fixture 40 and extends downward with pressure heads 90.

[0148] The leveling and pressure-applying mechanism can perform pressure bending deformation on the workpiece 50 to be leveled, which is accurately positioned and installed on the leveling fixture 40, in a specific concave-convex deformation area, so as to achieve the leveling operation of the specific concave-convex deformation area.

[0149] In the illustrated embodiment, the leveling device further includes:

[0150] The gantry 20 includes a crossbeam 70, and a leveling and pressure-applying mechanism is capable of horizontal movement along the crossbeam 70; and

[0151] The centering mechanism 60 is used to center and position the workpiece 50 to be leveled. The centering mechanism 60 is arranged on the outer periphery of the leveling fixture 40.

[0152] The centering mechanism 60, which can be a cylinder or similar device, can center and position the workpiece 50 to be leveled. After centering and positioning, the lifting and rotating part can rotate and accurately position the specific concave and convex deformation area of ​​the workpiece 50 to be leveled in the leveling position. Then, the leveling pressure mechanism can move horizontally along the crossbeam 70, moving the pressure head 90 directly above the leveling position.

[0153] Specifically, a hydraulically driven leveling method with higher pressure can be adopted. That is, the leveling and pressure application mechanism shown in the figure may include a hydraulic cylinder 100 and a servo motor 110 for driving the hydraulic cylinder 100 to move horizontally along the crossbeam 70. Under hydraulic drive, the piston rod of the hydraulic cylinder 100 can extend downward and push the pressure head 90 to apply pressure to the workpiece 50 to be leveled.

[0154] Furthermore, the leveling device may also include:

[0155] The workbench 30 is located below the crossbeam 70, and the leveling fixture 40 and the centering mechanism 60 are arranged on the workbench 30.

[0156] The base 10 and the worktable 30 are detachably mounted on the base 10;

[0157] The gantry 20 includes a U-shaped main frame, a crossbeam 70 spanning the top opening of the U-shaped main frame, and a base 10 located at the bottom of the U-shaped cavity within the U-shaped main frame. The base 10 is a base that bears the weight of the leveling machine and the leveling pressure. The worktable 30 can be detachably installed and positioned via a T-slot on the top, etc. The worktable 30 is used to install the leveling fixture 40 and the centering mechanism 60.

[0158] Figure 3 The leveling device also includes a flatness measuring instrument 80 disposed adjacent to the pressure head 90; and / or, the leveling device also includes a displacement sensor 120 disposed adjacent to the pressure head 90. The flatness measuring instrument 80 is used to measure the flatness of the workpiece 50 to be leveled, and the measurement result is compared with the acceptance criteria to determine whether the flatness is acceptable. If acceptable, leveling is not required. If unacceptable, leveling is required for the out-of-tolerance points (i.e., areas of uneven deformation).

[0159] In summary, the leveling fixture 40 according to the present invention can be used in conjunction with an automatic hydraulic leveling system to achieve automatic hydraulic leveling of the workpiece 50 to be leveled, thereby replacing manual leveling. It eliminates reliance on the operator's senses and experience, resulting in high efficiency and stable quality. The leveling fixture 40 has an automatic rotation function, which can be used with a flatness detector to achieve online real-time flatness detection and automatically position the workpiece to be leveled. Existing technologies require manual flatness detection and manual positioning of the workpiece to be leveled. The leveling fixture 40 has an automatic lifting function, allowing the workpiece 50 to be leveled to be in both lifting and lowering states. In the lifting state, the workpiece 50 can be automatically rotated; in the lowering state, leveling can be performed, protecting the lifting mechanism 160 and the rotating mechanism 150. The rotating mechanism 150 can use an asynchronous jog motor to switch between automatic and manual states. In automatic state, the workpiece 50 is automatically lifted and rotated during automatic leveling according to a pre-edited leveling program. In manual mode, it is manually controlled and can be moved continuously or in increments. The manual mode is mainly used for programming and teaching the automatic leveling system, and can also be used for manual-assisted leveling. The leveling fixture 40 of the present invention can achieve leveling in both concave and convex directions without flipping the workpiece 50 to be leveled. When it is necessary to perform convex leveling (reverse leveling) on ​​the workpiece 50 to be leveled, the top support boss 170 and the double-headed bracket can be introduced after the workpiece 50 to be leveled is rotated and positioned and before the pressure head 90 is pressed down, so as to achieve convex leveling (reverse leveling) of the workpiece 50 to be leveled without flipping the workpiece.

[0160] like Figure 11 As shown, in one specific embodiment, the present invention correspondingly proposes a plate deformation leveling method, comprising:

[0161] S100, Initially measure the flatness of the workpiece 50 to be leveled and determine whether it is qualified;

[0162] S200. When the flatness of the workpiece is not up to standard, determine the out-of-tolerance point and the initial deformation amount of the out-of-tolerance point;

[0163] S300. Calculate the workpiece leveling and reverse deformation amount based on the initial deformation amount of the defect.

[0164] S400: Control the pressure head 90 to align with the deviation point, and after contacting the deviation point, move towards the workpiece 50 to be leveled and apply pressure until the correction pressure stroke of the pressure head 90 reaches the leveling and anti-deformation amount of the workpiece. Then control the pressure head 90 to retract to complete one leveling operation.

[0165] As can be seen, the method of this invention requires an initial measurement of the workpiece flatness, followed by identification of the deviation points and precise calculation of the workpiece leveling deformation amount based on the initial deformation. After controlling the pressure head 90° to perform the leveling action, the sheet metal can achieve a basic leveling effect. The entire automated leveling operation process comprehensively includes control actions such as detection, judgment, calculation, and execution. Compared to existing manual operation methods, this undoubtedly greatly improves the efficiency of leveling work.

[0166] by Figure 1 , Figure 2 Taking the circular welded structure shown as an example, step S100 is used to initially measure the flatness of the circular surface on the circular plate 2 of the workpiece 50 to be leveled. Specifically, a flatness measuring instrument 80 can be used for the initial measurement, or other measuring devices can be used.

[0167] Step S100 also includes determining whether the initial flatness measurement result is acceptable. As an example, this determination can be made in conjunction with the displacement sensor 120; that is, step S100 includes:

[0168] The actual height A at the detection point on the surface of the workpiece 50 to be leveled was measured. i And using the height of the workpiece surface of the workpiece 50 to be leveled as the reference height A0, the initial deformation F at the detection point is obtained. i =A0-A i ;

[0169] The maximum absolute value of the initial deformation at each test point on the workpiece surface is compared with the set flatness standard value to determine whether the workpiece flatness is qualified.

[0170] Specifically, when the annular plate 2 of the workpiece 50 to be leveled is rotated, the displacement sensor 120, which is stationary directly above the annular plate 2, can initially measure the reference height and actual height of each detection point on the annular surface, thereby obtaining the initial deformation at each point on the annular surface. If the largest absolute value among the initial deformations exceeds the standard, then the flatness is obviously unqualified.

[0171] Step S200 is used to determine the out-of-tolerance point and the initial deformation amount of the out-of-tolerance point; the criterion for determining the out-of-tolerance point is: the initial deformation amount F at the detection point. i If the absolute value of the deviation exceeds the set deviation standard value, the detection point is determined to be an out-of-tolerance point. In other words, among all detection points, those with excessive concave-convex deformation are considered out-of-tolerance points.

[0172] Of course, those skilled in the art will understand that methods such as taking pictures or scanning can also be used to collect planar information or out-of-tolerance information, and then to conduct preliminary flatness measurement, identify out-of-tolerance points, etc.

[0173] Step S300 is used to calculate the workpiece leveling reverse deformation amount based on the initial deformation amount of the deviation point. In other words, in cases of overcorrection, a large initial deformation amount leads to a proportionally larger reverse correction deformation amount (opposite to the initial deformation direction), resulting in a larger workpiece leveling reverse deformation amount. Therefore, the downward movement of the pressure head 90 should also be greater. See also Figure 9 , Figure 10 The overpressure position A2 shown is the stop position of the pressure head, and the maximum downward pressure distance between the overpressure position A2 and the initial position A1 before leveling is the workpiece leveling reverse deformation amount.

[0174] Step S400 is used to precisely control the pressure head 90 that aligns with the out-of-tolerance points, performing a leveling operation on the out-of-tolerance points. Figure 10 For example, the corrective pressure stroke of the pressure head 90 starts from the contact point of the excess, that is, from the initial position A1 before leveling when the pressure head 90 contacts the pressure head 90 until the pressure head 90 reaches the leveling overpressure position A2. The entire corrective pressure stroke is equal to the aforementioned workpiece leveling reverse deformation amount. After the pressure head 90 reaches the leveling overpressure position A2, the leveling overpressure position A2 is the pressure head stop position. Then, the pressure head 90 is controlled to retract, completing one leveling operation.

[0175] Mechanical leveling is an elastoplastic mechanical behavior, involving a complete loading and unloading process. During loading, the pressure head 100 moves downward and applies downward pressure to the workpiece, inducing a certain amount of plastic deformation in a localized area. Before calling the leveling process parameters, based on input conditions such as the metal material, plate thickness, and initial deformation, the software automatically calculates the reverse deformation amount of the workpiece to be leveled. When the displacement sensor 120 on the pressure head 90 detects the predetermined height value, the hydraulic pressure head stops pressing down and moves upward to the original height position. After the pressure head is unloaded, the workpiece will recover its elastic deformation, but the residual plastic deformation value is equivalent to the initial deformation value of the workpiece, for example, returning to... Figure 10 The springback position A1 shown after leveling is basically flush with the surface of the workpiece, thus achieving the leveling of the workpiece.

[0176] Therefore, the amount of reverse deformation during workpiece leveling is proportional to the initial deformation and can be obtained empirically. However, in this embodiment, a quantitative calculation is used, meaning that the amount of reverse deformation during workpiece leveling at the point of deviation satisfies:

[0177] l=k·t·σ s +F;

[0178] Where l is the amount of reverse deformation during leveling of the workpiece with excessive defects, t is the thickness of the workpiece to be leveled (50 mm), and σ s The yield strength of the workpiece 50 to be leveled is given by k, the material coefficient is given by F, and the initial deformation of the deviation point is given by F. This can be detected by, for example, laser scanning of the workpiece surface by a flatness measuring instrument 80.

[0179] Because of the difference between concave deformation and convex deformation, before the pressure head 90 is aligned with the deviation point and moves towards the workpiece 50 to be leveled to apply pressure, the leveling direction of the deviation point should be determined according to the initial deformation type of the deviation point; and in response to the determined leveling direction, the corresponding leveling fixture 40 that is used in conjunction with the pressure head 90 should be retrieved.

[0180] Specifically, the actual height of the deviation point and the reference height based on the height of the workpiece surface of the workpiece 50 to be leveled can be measured first. The initial deformation type of the deviation point can be determined by comparing the actual height with the reference height. If it is determined to be a concave deformation, the convex leveling component can be called; if it is determined to be an convex deformation, the concave leveling component can be called accordingly, and the called leveling component can be moved to the leveling position.

[0181] See Figure 12 Before step S100, which involves initially measuring the flatness of the workpiece 50 to be leveled and determining whether it is qualified, the workpiece 50 to be leveled should be moved to the tooling platform 130 and centered. After determining that the flatness of the workpiece 50 to be leveled is unqualified, the excess point should be rotated to the leveling position on the tooling platform 130 to facilitate the leveling operation.

[0182] It should be noted that not all defects can be basically corrected with a single leveling operation. If the flatness is still unacceptable after one operation, the leveling operation needs to be repeated. Therefore, the method of this invention also includes:

[0183] After completing one leveling operation, the flatness of the workpiece 50 to be leveled is re-measured, and if the flatness of the re-measured workpiece is still unqualified, the next leveling operation is repeated.

[0184] Based on the above-mentioned plate deformation leveling method, the present invention discloses a leveling device, comprising:

[0185] Leveling fixture 40, used to support and position the workpiece 50 to be leveled;

[0186] A leveling and pressure-applying mechanism is arranged at a distance from the leveling fixture 40 and includes a pressure head 90 extending toward the leveling fixture 40;

[0187] Displacement sensor 120 is used to detect the position of the pressure head;

[0188] Flatness measuring instrument 80; and

[0189] The controller is configured as follows:

[0190] Use the flatness testing instrument 80 to initially measure the flatness of the workpiece 50 to be leveled;

[0191] Determine if the workpiece flatness is unqualified, and identify the point of deviation and the initial deformation of the point of deviation;

[0192] Calculate the workpiece leveling reverse deformation amount based on the initial deformation amount of the defect point;

[0193] Control the leveling and pressure application mechanism to drive the pressure head 90 to align and contact the deviation point, and then move towards the workpiece 50 to be leveled to apply pressure.

[0194] Combined with displacement sensor 120, the pressure head 90 stops and retracts after reaching the amount of workpiece leveling and reverse deformation, thus completing one leveling operation.

[0195] In this invention, a controller, in conjunction with a flatness detector 80 and a displacement sensor 120, executes each step of the aforementioned plate deformation leveling method. Thus, a leveling device capable of achieving efficient and high-precision automated leveling operation is designed. Specifically, automated detection and leveling operations can be performed by combining detection elements and a controller that executes set control logic, as will be described in detail below.

[0196] In comparison, existing pressure straightening processes are often performed manually, relying on the operator's feel and experience, resulting in low efficiency, inconsistent quality, and high labor intensity. The leveling device of this invention, however, is simple in composition, highly efficient, and can meet the high-quality, high-efficiency, and rapid production requirements of modern enterprises.

[0197] Similarly, the leveling deformation of workpieces with substandard performance must meet the following requirements:

[0198] l=k·t·σ s +F;

[0199] Where l is the amount of reverse deformation during leveling of the workpiece with excessive defects, t is the thickness of the workpiece to be leveled (50 mm), and σ s Let be the yield strength of the workpiece 50 to be leveled, k be the material coefficient, and F be the initial deformation of the deviation point.

[0200] The process of determining whether a workpiece's flatness is unacceptable, and identifying the point of deviation and its initial deformation, also includes:

[0201] The actual height A at the detection point on the surface of the workpiece 50 to be leveled was measured. i And using the height of the workpiece surface of the workpiece 50 to be leveled as the reference height A0, the initial deformation F at the detection point is obtained. i =A0-A i ;

[0202] If the absolute value of the initial deformation at each test point on the workpiece surface is greater than the set flatness standard value, the workpiece flatness is deemed unqualified.

[0203] Determine the initial deformation F at the detection pointi If the absolute value is greater than the set out-of-tolerance standard value, the detection point is determined to be an out-of-tolerance point.

[0204] Furthermore, the controller is also configured to:

[0205] Before controlling the leveling and pressure application mechanism to drive the pressure head 90 to align with the deviation point and move towards the workpiece 50 to be leveled and apply pressure, the leveling direction of the deviation point is determined according to the initial deformation type of the deviation point.

[0206] In response to the determined leveling direction, the corresponding leveling fixture 40 that is used in conjunction with the pressure head 90 is retrieved.

[0207] More specifically, before controlling the leveling and pressure-applying mechanism to drive the pressure head 90 to align with the deviation point and move towards the workpiece 50 to be leveled and apply pressure, the leveling direction of the deviation point is determined according to the initial deformation type of the deviation point, including;

[0208] Control the flatness measuring instrument 80 to measure the actual height at the point of deviation and the reference height based on the height of the workpiece surface of the workpiece 50 to be leveled;

[0209] The initial deformation type of the deviation point is determined by comparing the actual height with the reference height.

[0210] Among them, in response to the determined leveling direction, the corresponding leveling fixture 40 used in conjunction with the pressure head 90 includes:

[0211] When the leveling direction is determined to be upward convex deformation, the concave leveling component is retrieved.

[0212] When the leveling direction is determined to be concave deformation, the convex leveling component is retrieved.

[0213] Specifically, the leveling tooling 40 includes:

[0214] Tooling platform 130, with multiple sets of convex leveling components arranged symmetrically about the platform center about the top platform surface of tooling platform 130; and

[0215] The lifting and rotating part is arranged on the top platform surface of the tooling platform 130 and is used to drive the workpiece 50 to be leveled to lift and / or rotate.

[0216] Furthermore, the workpiece 50 to be leveled is a circular welded structure and includes:

[0217] Circular plate 1; and

[0218] A circular ring plate 2 is welded to the surface of a circular plate 1. An outer ring fillet weld 3 is formed between the outer edge of the circular ring plate 2 and the surface of the circular plate 1, and an inner ring fillet weld 4 is formed between the inner edge of the circular ring plate 2 and the surface of the circular plate 1.

[0219] Based on this, the flatness of the workpiece 50 to be leveled is initially measured using the flatness testing instrument 80, including:

[0220] Move the workpiece 50 to be leveled onto the tooling platform 130;

[0221] Move the flatness measuring instrument 80 directly above the annular plate 2;

[0222] Control the lifting and rotating part to lift and rotate the workpiece 50 to be leveled, so as to cooperate with the flatness measuring instrument 80 to initially measure the flatness of the workpiece;

[0223] Furthermore, determining whether a workpiece's flatness is unacceptable, and identifying the point of deviation and its initial deformation, also includes:

[0224] After identifying the deviation point, control the lifting and rotating part to lift and rotate the workpiece to be leveled 50, so that the deviation point moves to the leveling position.

[0225] Specifically, the leveling device also includes:

[0226] Centering mechanism 60 is used to center and position the workpiece 50 to be leveled. Centering mechanism 60 is arranged on the outer periphery of leveling fixture 40.

[0227] Based on this, moving the workpiece 50 to be leveled onto the tooling platform 130 also includes:

[0228] Control the centering mechanism 60 to center and position the workpiece 50 to be leveled on the tooling platform 130.

[0229] Specifically, the leveling device also includes:

[0230] The gantry 20 includes a crossbeam 70, and the leveling and pressure-applying mechanism is capable of moving horizontally along the crossbeam 70 to drive the pressure head 90 and the adjacent flatness detector 80 and displacement sensor 120 to move horizontally.

[0231] Based on this, controlling the leveling and pressure-applying mechanism to drive the pressure head 90 to align with the deviation point and move towards the workpiece 50 to apply pressure also includes:

[0232] The leveling and pressure-applying mechanism is controlled to move horizontally along the crossbeam 70, so as to move the displacement sensor 120, the flatness detector and the displacement sensor 120 to the leveling position.

[0233] See Figure 3 The leveling device may also include:

[0234] The workbench 30 is located below the crossbeam 70, and the leveling fixture 40 and the centering mechanism 60 are arranged on the workbench 30.

[0235] The base 10 and the worktable 30 are detachably mounted on the base 10;

[0236] The gantry 20 includes a U-shaped main frame, a crossbeam 70 spanning the top opening of the U-shaped main frame, and a base 10 located at the bottom of the U-shaped cavity within the U-shaped main frame.

[0237] In this embodiment, the leveling device is hydraulically driven, and the leveling pressure mechanism may include a hydraulic cylinder 100 and a servo motor for driving the hydraulic cylinder 100 to move horizontally along the crossbeam 70. Under hydraulic drive, the piston rod of the hydraulic cylinder 100 can extend downward and push the pressure head 90 to apply pressure to the workpiece 50 to be leveled; and / or, the flatness detector 80 is a line laser scanner or a three-dimensional vision camera.

[0238] The hydraulic cylinder and pressure head are controlled by a servo motor to move along the crossbeam, so that the pressure head is directly above the workpiece to be leveled, and the leveling of workpieces with different diameters is also achieved.

[0239] To enable automatic cyclic operation, the controller is also configured as follows:

[0240] After completing one leveling operation, the flatness of the workpiece 50 to be leveled is re-measured, and if the flatness of the re-measured workpiece is not up to standard, the next leveling operation is repeated.

[0241] During operation, the hydraulic cylinder 100 and the pressure head 90, driven by the servo motor 110, can move laterally along the crossbeam 70 to align directly above the workpiece 50 to be leveled. The hydraulic cylinder 100 controls the pressure head 90 to descend and rise via the hydraulic cylinder piston rod. When the pressure head 90 descends, it applies pressure to the leveling fixture 40 and the workpiece 50 to be leveled. The leveling fixture 40 and the workpiece 50 interact, causing deformation of the workpiece 50, thereby achieving leveling. After the workpiece 50 is leveled, its flatness is checked again to determine whether further leveling is needed.

[0242] In addition, the present invention provides a machine-readable storage medium storing instructions that, when executed by a processor, enable the processor to perform the above-described board deformation leveling method.

[0243] See Figure 12 , Figure 3 More specifically, during the leveling operation, firstly, the flatness measuring instrument 80 is controlled to initially measure the flatness of the workpiece 50 to be leveled; this includes moving the workpiece 50 to be leveled onto the tooling platform 130; controlling the centering mechanism 60 to center and position the workpiece 50 to be leveled onto the tooling platform 130. The flatness measuring instrument 80 is then moved directly above the annular plate 2; the lifting and rotating part is controlled to raise and rotate the workpiece 50 to cooperate with the initial flatness measurement by the flatness measuring instrument 80.

[0244] Secondly, determine if the workpiece flatness is unqualified, and identify the out-of-tolerance point and its initial deformation; specifically, measure the actual height A at the detection point on the surface of the workpiece 50 to be leveled. i And using the height of the workpiece surface of the workpiece 50 to be leveled as the reference height A0, the initial deformation F at the detection point is obtained. i =A0-A i If the absolute value of the initial deformation at each detection point on the workpiece surface is greater than the set flatness standard value, the workpiece flatness is deemed unqualified; determine the initial deformation F at the detection point. i If the absolute value of the deviation exceeds the set outdated standard value, the detection point is identified as an out-of-tolerance point. After identifying the out-of-tolerance point, the lifting and rotating unit is controlled to lift and rotate the workpiece to be leveled by 50 degrees, so that the out-of-tolerance point moves to the leveling position.

[0245] Then, based on the initial deformation of the defective part, the workpiece leveling and reverse deformation amount of the defective part is calculated.

[0246] Then, based on the initial deformation type of the out-of-tolerance point, the leveling direction of the out-of-tolerance point is determined; this includes controlling the flatness testing instrument to measure the actual height at the out-of-tolerance point and the reference height based on the height of the workpiece surface of the workpiece 50 to be leveled; and determining the initial deformation type of the out-of-tolerance point by comparing the actual height with the reference height.

[0247] Specifically, in response to the determined leveling direction, the corresponding leveling fixture 40 that is used in conjunction with the pressure head 90 is retrieved. This includes retrieving a concave leveling component when the leveling direction is determined to be convex deformation, and retrieving an convex leveling component when the leveling direction is determined to be concave deformation.

[0248] Finally, the leveling and pressure-applying mechanism is controlled to drive the pressure head 90 to align with the deviation point and move towards the workpiece 50 to apply pressure. This includes controlling the leveling and pressure-applying mechanism to move horizontally along the crossbeam 70, so as to move the pressure head 90, the flatness detector 80, and the displacement sensor 120 to the leveling position. Then, in conjunction with the displacement sensor 120, the pressure head 90 is controlled to move downward to apply pressure and stop and retract after completing a correction pressure stroke equal to the amount of reverse deformation of the workpiece, thus completing one leveling operation.

[0249] After completing one leveling operation, the flatness of the workpiece 50 to be leveled is re-measured. If the flatness of the re-measured workpiece is not up to standard, the next leveling operation is repeated until the leveling operation is completed.

[0250] In summary, this invention achieves automatic hydraulic leveling of medium and heavy plates through automatic workpiece positioning, automatic workpiece flatness detection, calculation of workpiece leveling deformation, precise stopping position of the pressure head during leveling, and re-measurement of workpiece flatness after leveling. This replaces manual leveling, eliminates reliance on operator feel and experience, and offers high efficiency and stable quality.

[0251] It should be noted that a displacement sensor can be used to detect the descent height of the pressure head during leveling, thereby precisely controlling the pressure stroke of the pressure head during leveling. The hydraulic cylinder can be a digital cylinder, so that the piston rod of the hydraulic cylinder moves according to the command, which can achieve high-precision stopping of the pressure head and precise control of the amount of workpiece deformation, resulting in a precise leveling effect, while also preventing the occurrence of severe workpiece deformation due to overpressure.

[0252] In addition, the aforementioned method uses line laser scanning to scan the height of the workpiece (the reinforcing ring area of ​​the welded assembly) to achieve flatness detection. Flatness measurement can also be achieved through 3D vision photography.

[0253] In the description of this invention, it should be understood that the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this invention, "a plurality of" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0254] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection, an electrical connection, or a connection that allows communication between them; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0255] In the description of this specification, the references to terms such as "one embodiment," "some embodiments," "example," "specific example," or "some examples," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples. Moreover, without contradiction, those skilled in the art can combine and integrate the different embodiments or examples described in this specification, as well as the features of different embodiments or examples.

[0256] Although embodiments of the present invention have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting the present invention. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of the present invention.

Claims

1. A method for leveling deformed sheet metal, characterized in that, The method includes: Initially measure the flatness of the workpiece (50) to be leveled and determine whether it is qualified; In the case where the flatness of the workpiece is unqualified, determine the out-of-tolerance point and the initial deformation amount of the out-of-tolerance point; Based on the initial deformation amount of the out-of-tolerance point, calculate the workpiece leveling reverse deformation amount of the out-of-tolerance point; The pressure head (90) is aligned with the deviation point and, after contacting the deviation point, is applied to the workpiece (50) to be leveled for correction until the correction pressure stroke of the pressure head (90) reaches the leveling deformation amount of the workpiece. Then the pressure head (90) is controlled to retract to complete one leveling operation.

2. The plate deformation leveling method according to claim 1, characterized in that, The workpiece leveling deformation amount for the out-of-tolerance point satisfies: ； Where l is the amount of reverse deformation of the workpiece at the point of excess, t is the plate thickness of the workpiece (50) to be leveled, and σ s is the yield strength of the workpiece (50) to be leveled, k is the material coefficient, and F is the initial deformation of the defect point.

3. The plate deformation leveling method according to claim 1, characterized in that, The steps for initially measuring the flatness of the workpiece (50) to be leveled and determining whether it is qualified include: The actual height A at the detection point on the surface of the workpiece to be leveled (50) was measured. i And using the surface height at the workpiece detection point of the workpiece to be leveled (50) as the reference height A0, the initial deformation F at the detection point is obtained. i =A0-A i ; The maximum absolute value of the initial deformation at each detection point on the workpiece surface is compared with the set flatness standard value to determine whether the workpiece flatness is qualified.

4. The plate deformation leveling method according to claim 3, characterized in that, In the case of workpiece flatness non-compliance, the steps for determining the out-of-tolerance point and the initial deformation amount of the out-of-tolerance point include: The initial deformation F at the detection point i If the absolute value of the error is greater than the set out-of-tolerance standard value, the detection point is determined to be the out-of-tolerance point.

5. The plate deformation leveling method according to claim 1, characterized in that, The method further includes: Before controlling the pressure head (90) to align the out-of-tolerance point and move towards the workpiece (50) to apply pressure, the straightening direction of the out-of-tolerance point is determined according to the initial deformation type of the out-of-tolerance point; In response to the determined leveling direction, the corresponding leveling fixture (40) that is used in conjunction with the pressure head (90) is retrieved.

6. The plate deformation leveling method according to claim 5, characterized in that, Before controlling the pressure head (90) to align the deviation point and move towards the workpiece (50) to apply pressure, the step of determining the leveling direction of the deviation point based on the initial deformation type of the deviation point further includes: The actual height at the point of deviation and the reference height based on the surface height at the workpiece detection point of the workpiece to be leveled (50) are measured. The initial deformation type of the out-of-tolerance point is determined by comparing the actual height with the reference height.

7. The plate deformation leveling method according to claim 1, characterized in that, The workpiece (50) to be leveled is a circular welded structure and includes: Circular plate (1); and A circular ring plate (2) is welded to the surface of the circular plate (1). An outer ring fillet weld (3) is formed between the outer edge of the circular ring plate (2) and the surface of the circular plate (1). An inner ring fillet weld (4) is formed between the inner edge of the circular ring plate (2) and the surface of the circular plate (1). The method further includes: Before the initial measurement of the flatness of the workpiece (50) to be leveled and the determination of whether it is qualified, the workpiece (50) to be leveled is moved to the tooling platform (130) and positioned. After determining that the flatness of the workpiece (50) to be leveled is not up to standard, the point of excess is rotated to the leveling position on the tooling platform (130).

8. The plate deformation leveling method according to claim 7, characterized in that, The workpiece (50) to be leveled is a medium-thick plate of 30~80mm.

9. The plate deformation leveling method according to any one of claims 1 to 8, characterized in that, The method further includes: After completing one leveling operation, the flatness of the workpiece to be leveled (50) is re-measured, and if the flatness of the re-measured workpiece is still unqualified, the next leveling operation is repeated.

10. A leveling device, characterized in that, The leveling device includes: A leveling fixture (40) is used to support and position the workpiece (50) to be leveled. The leveling and pressure-applying mechanism is arranged at a distance from the leveling fixture (40) and includes a pressure head (90) extending toward the leveling fixture (40). Displacement sensor (120) is used to detect the position of the pressure head; Flatness measuring instrument (80); and The controller is configured as follows: Control the flatness testing instrument (80) to initially measure the flatness of the workpiece (50) to be leveled; The workpiece is determined to be non-compliant in terms of flatness, and the point of deviation and the initial deformation of the point of deviation are identified. Based on the initial deformation amount of the out-of-tolerance point, calculate the workpiece leveling reverse deformation amount of the out-of-tolerance point; Control the leveling and pressure mechanism to drive the pressure head (90) to align and contact the out-of-tolerance point, and then apply corrective pressure toward the workpiece (50) to be leveled; Combined with the displacement sensor (120), the pressure head (90) is controlled to stop and retract after reaching the amount of workpiece leveling and anti-deformation, thus completing one leveling operation.

11. The leveling device according to claim 10, characterized in that, The workpiece leveling deformation amount for the out-of-tolerance point satisfies: ； Where l is the amount of reverse deformation of the workpiece at the point of excess, t is the plate thickness of the workpiece (50) to be leveled, and σ s is the yield strength of the workpiece (50) to be leveled, k is the material coefficient, and F is the initial deformation of the defect.

12. The leveling device according to claim 10, characterized in that, Determining that the flatness of the workpiece is unqualified, and identifying the point of deviation and the initial deformation of the point of deviation, includes: The actual height A at the detection point on the surface of the workpiece to be leveled (50) was measured. i And using the surface height at the workpiece detection point of the workpiece to be leveled (50) as the reference height A0, the initial deformation F at the detection point is obtained. i =A0-A i ; If the absolute value of the initial deformation at each detection point on the surface of the workpiece is greater than the set flatness standard value, the workpiece flatness is deemed unqualified. Determine the initial deformation F at the detection point. i If the absolute value of the error is greater than the set out-of-tolerance standard value, the detection point is determined to be the out-of-tolerance point.

13. The leveling device according to claim 10, characterized in that, The controller is also configured to: Before controlling the leveling and pressing mechanism to drive the pressure head (90) to align the out-of-tolerance point and move towards the workpiece (50) to apply pressure, the leveling direction of the out-of-tolerance point is determined according to the initial deformation type of the out-of-tolerance point. In response to the determined leveling direction, the corresponding leveling fixture (40) that is used in conjunction with the pressure head (90) is retrieved.

14. The leveling device according to claim 13, characterized in that, Before controlling the leveling and pressing mechanism to drive the pressure head (90) to align the deviation point and move towards the workpiece (50) to apply pressure, the leveling direction of the deviation point is determined according to the initial deformation type of the deviation point, including: Control the flatness tester (80) to measure the actual height at the out-of-tolerance point and the reference height based on the surface height at the workpiece test point of the workpiece to be leveled (50); The initial deformation type of the out-of-tolerance point is determined by comparing the actual height with the reference height.

15. The leveling device according to claim 13, characterized in that, The leveling fixture (40) includes: An upwardly convex leveling assembly is used to level the concave deformation of the workpiece (50) to be leveled. The upwardly convex leveling assembly includes a top support boss (170) supporting the workpiece (50) from below and a pressure support bracket (180) arranged above the workpiece (50) to receive the leveling pressure. The bottom of the pressure support bracket (180) is provided with a plurality of horizontally spaced and downwardly extending abutting ends (181). The top support boss (170) is arranged below the pressure support bracket (180) and located in the horizontally spaced space between adjacent abutting ends (181). A concave leveling assembly is used to level the convex deformation of the workpiece (50) to be leveled. The concave leveling assembly is arranged below the workpiece (50) to be leveled and includes a plurality of leveling supports (140) arranged laterally at intervals. Furthermore, the process of retrieving the leveling direction in response to the determination, and using the corresponding leveling fixture (40) that cooperates with the pressure head (90), includes: When the leveling direction is determined to be an upward convex deformation, the downward concave leveling component is retrieved; When the leveling direction is determined to be a concave deformation, the convex leveling component is retrieved.

16. The leveling device according to claim 15, characterized in that, The leveling fixture (40) includes: Tooling platform (130), multiple sets of the aforementioned convex leveling components are arranged on the top platform surface of the tooling platform (130) and symmetrically about the platform center of the top platform surface; and A lifting and rotating part is arranged on the top platform surface of the tooling platform (130) and is used to drive the workpiece (50) to be leveled to lift and / or rotate. Furthermore, the workpiece to be leveled (50) is a circular welded structure and includes: Circular plate (1); and A circular ring plate (2) is welded to the surface of the circular plate (1). An outer ring fillet weld (3) is formed between the outer edge of the circular ring plate (2) and the surface of the circular plate (1). An inner ring fillet weld (4) is formed between the inner edge of the circular ring plate (2) and the surface of the circular plate (1). Furthermore, the control of the flatness testing instrument (80) to initially measure the flatness of the workpiece (50) to be leveled includes: Move the workpiece (50) to be leveled onto the tooling platform (130); Move the flatness measuring instrument (80) directly above the annular plate (2); The lifting and rotating part is controlled to lift and rotate the workpiece (50) to be leveled, so as to cooperate with the flatness measuring instrument (80) to initially measure the flatness of the workpiece; Furthermore, the step of determining that the flatness of the workpiece is unqualified and identifying the out-of-tolerance point and the initial deformation amount of the out-of-tolerance point also includes: After determining the deviation point, the lifting and rotating part is controlled to lift and rotate the workpiece (50) to be leveled, so that the deviation point moves to the leveling position.

17. The leveling device according to claim 16, characterized in that, The leveling device includes: A centering mechanism (60) is used to center and position the workpiece (50) to be leveled. The centering mechanism (60) is arranged on the outer periphery of the leveling fixture (40). Furthermore, moving the workpiece (50) to be leveled onto the tooling platform (130) also includes: Control the centering mechanism (60) to center and position the workpiece (50) to be leveled on the tooling platform (130).

18. The leveling device according to claim 17, characterized in that, The leveling device also includes: The gantry (20) includes a crossbeam (70), and the leveling and pressing mechanism is capable of moving horizontally along the crossbeam (70) to drive the pressure head (90) and the adjacent flatness detector (80) and displacement sensor (120) to move horizontally; Furthermore, controlling the leveling and pressure-applying mechanism to drive the pressure head (90) to align with the deviation point and move towards the workpiece (50) to apply pressure also includes: The leveling and pressure-applying mechanism is controlled to move horizontally along the crossbeam (70) to move the displacement sensor (120), the flatness detector and the displacement sensor (120) to the leveling position.

19. The leveling device according to claim 18, characterized in that, The leveling device also includes: The workbench (30) is located below the crossbeam (70), and the leveling fixture (40) and the centering mechanism (60) are arranged on the workbench (30); The base (10) and the worktable (30) are detachably mounted on the base (10); The gantry (20) includes a U-shaped main frame, the crossbeam (70) spans the top opening of the U-shaped main frame, and the base (10) is located at the bottom of the U-shaped cavity within the U-shaped main frame.

20. The leveling device according to claim 18, characterized in that, The leveling and pressure-applying mechanism includes a hydraulic cylinder (100) and a servo motor for driving the hydraulic cylinder (100) to move horizontally along the crossbeam (70). Under hydraulic drive, the piston rod of the hydraulic cylinder (100) can extend downward and push the pressure head (90) to apply pressure to the workpiece (50) to be leveled; and / or The flatness testing instrument (80) is a line laser scanner or a three-dimensional vision camera.

21. The leveling device according to any one of claims 10 to 20, characterized in that, The controller is also configured to: After completing one leveling operation, the flatness of the workpiece to be leveled (50) is re-measured, and if the flatness of the re-measured workpiece is not qualified, the next leveling operation is repeated.

22. A machine-readable storage medium, characterized in that, The machine-readable storage medium stores instructions that, when executed by a processor, enable the processor to perform the plate deformation leveling method according to any one of claims 1 to 9.

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