A highly integrated aviation hydraulic plunger pump repair line and its use method

Abstract

The present invention relates to the field of repair lines, and specifically to a highly integrated aviation hydraulic plunger pump repair line and a method for using the same. The aviation hydraulic plunger pump repair line is based on an MES system and includes an automatic transfer AGV, a storage vertical warehouse, and further includes: a disassembly and cleaning workstation, an automatic cleaning workstation, a fault inspection workstation, a repair workstation, an automatic cleaning workstation, an assembly workstation, a storage vertical warehouse, and a visual inspection error-proofing camera. The specific steps of the line are as follows: S001, disassembly and cleaning work; S002, automatic cleaning work; S003, fault inspection work; S004, repair work; S005, automatic transfer work; S006, visual inspection work; S007, storage vertical warehouse work; S008, assembly work. The present invention improves the disadvantages of manual work, assists the manual repair process, forms modular processes and standards, standardizes the work process, and stabilizes product quality; reduces the manual collection of production data, improves production efficiency, reduces the probability of error, and forms a suitable information feedback system.

Description

Technical Field

[0001] The invention relates to the field of repair lines, in particular to a highly integrated aviation hydraulic plunger pump repair line and a use method thereof. Background Art

[0002] The hydraulic piston pump is the heart of the aircraft hydraulic system, providing pressure. Its performance directly impacts system operation, making repairs difficult and risky. Currently, the unit primarily operates a single-person repair model, encompassing basic procedures such as disassembly, cleaning, troubleshooting, repair, assembly, and testing. These procedures are dispersed across separate workstations, with no connections between them. Manual transfer to the next process is required upon completion of the previous one. Furthermore, tooling is stored in individual tool cabinets, where tools for different processes are mixed. During each process, they are manually retrieved, brought to the workstation for repair, and returned to the tool cabinet. The hydraulic piston pump repair process is complex, requires high quality standards, and requires strict documentation to ensure completeness. Therefore, the introduction of automated and intelligent technologies is urgently needed to significantly improve the efficiency of existing production lines, reduce labor costs, enhance product repair quality, and improve departmental operations and management, ultimately achieving lean production management. Summary of the Invention

[0003] In order to solve the above problems, the present invention provides a highly integrated aviation hydraulic plunger pump repair line and a method for using the same.

[0004] A highly integrated aviation hydraulic piston pump repair line, based on the MES system, includes automated transfer AGVs, a storage system, and:

[0005] The disassembly and cleaning workstation, automatic cleaning workstation, fault inspection workstation, and repair workstation are each equipped with a buffer channel, and the material is transported between the storage warehouse through a combination of automatic transfer AGV and manual transfer;

[0006] The automatic cleaning workstation is connected to the disassembly and cleaning workstation through a bull's eye platform to perform fine cleaning on parts after rough disassembly and before assembly;

[0007] At the assembly workstation, after all parts are assembled, they are transported via roller conveyors for assembly;

[0008] The storage warehouse is directly connected to the assembly workstation through a roller conveyor;

[0009] The visual inspection error-proofing camera checks for missing parts against the template before storage, and sends the results back to the MES system for requesting missing parts.

[0010] The decomposition and cleaning workstation includes a terminal device that transmits production task-related information to the production station in accordance with the process sequence, a dual-axis positioner that automatically rotates to a suitable position according to the work step for easy decomposition, an electric tightening shaft that automatically decomposes various fasteners, a single-axis positioner for receiving the decomposed upper end cover, a servo puller and press and disassembly tooling that cooperate with pulling out internal parts to continue decomposition, a manual operating table and a gas-liquid booster cylinder press for decomposing some assemblies, and an ultrasonic cleaning machine for rough cleaning of workpieces.

[0011] The automatic cleaning workstation operates in a vacuum-sealed working chamber through flushing and soaking, rotating and rocking movements of parts, steam degreasing, and vacuum drying.

[0012] The fault inspection workstation includes a controller for executing system instructions, a table fixture for clamping parts to ensure that the parts are fixed during measurement, a cache station for temporarily storing parts to be measured, an automatic pallet transport line for automatically transporting the temporarily stored parts into a constant temperature room for measurement, a three-coordinate automatic measuring machine for directly measuring the dimensions of parts, and a sensor for measuring the temperature and humidity in the room for transmitting temperature and humidity data for room temperature and humidity control.

[0013] The repair workstation includes a workbench for placing parts to be repaired, a roughness detector for checking the surface roughness of parts, a flatness detector for checking the flatness of parts, an ultrasonic automatic quick washing table for cleaning the grinding paste and ensuring that the surface of parts is clean and free of impurities, a three-degree-of-freedom manipulator for clamping parts, a workpiece grinding table for repairing parts, a qualified workbench for placing qualified parts, and a software cabinet for implementing command control.

[0014] The assembly workstation includes a servo press and a servo electric push cylinder for automated auxiliary assembly work, a visual inspection camera for detecting the completeness of parts, a conveyor line for automatically inputting part trays from the storage warehouse into the assembly line, an auxiliary workbench for assembly and repair of small parts, a spring press for measuring spring force, a positioner that automatically changes its posture to cooperate with the assembly movements of personnel, a power-assisted hoist for transferring large parts, and tooling tools with the ability to meet the detection requirements of the assembly process.

[0015] The storage vertical warehouse includes a vertical warehouse protective glass room, a pneumatic jacking platform for temporary interception and visual photography identification, an automatic conveyor line for warehousing and a manual and automatic conveyor line connected to the warehousing conveyor line, an automatic conveyor line for receiving pallets, a stacker for delivering pallets, and a first row of shelves and a second row of shelves arranged on both sides of the stacker track.

[0016] A highly integrated method for using an aviation hydraulic plunger pump repair line, the specific steps are as follows:

[0017] S001. Decomposition and cleaning work:

[0018] After completing production dispatch through the MES system, the relevant information of the production task is transmitted to the terminal equipment at the production station;

[0019] Workers can view the corresponding production tasks, related attachment information, and production preparation information through terminal devices, and then click to receive task instructions to start the attachment decomposition work;

[0020] According to the digital process flow of the product on the terminal device, the work content is prompted one by one. The workstation is equipped with semi-automatic clamping equipment and customized tool tables. After each decomposed process is completed, the system prompts the work content and required tools of the next process;

[0021] After the automatic transfer AGV transfers the pump material to be repaired to the disassembly station, the disassembly station lifts the workpiece, and the operator fixes the workpiece together with the dual-axis positioner and begins the disassembly work. The dual-axis positioner automatically rotates to the appropriate position according to the work step to facilitate disassembly, and uses the electric tightening spindle to automatically disassemble various fasteners;

[0022] The disassembled upper end cover is transferred to a single-axis positioner and automatically rotated to the appropriate position. The internal parts are pulled out and further disassembled using a servo puller and disassembly tooling. Some assemblies are disassembled using a manual operating table and a gas-liquid booster cylinder press.

[0023] The disassembled parts are stored in a special material tray and can be easily transferred to the rough cleaning station on the non-powered material channel. The lifting platform descends and the workpiece is sent into the ultrasonic cleaning machine. After a period of rough cleaning, it rises and the parts are manually blown dry.

[0024] After the rough cleaning is completed, the parts are picked up manually and placed one by one in the material tray inside the buffer channel. After the rough cleaning, they can be directly put into storage or automatically cleaned. The disassembly process is carried out according to the material inventory of each step, and the specific operation content of each step is prompted according to the terminal equipment process;

[0025] After disassembly, the parts are placed in a dedicated cleaning box and transported to the cleaning area. Information data such as material anomalies during the disassembly process is uploaded through various means to form a complete digital disassembly process and achieve data traceability.

[0026] S002, automatic cleaning work:

[0027] The cleaning process is carried out under vacuum. Organic solvents or modified alcohols are used as cleaning media, and inorganic solvents can also be used as auxiliary agents. The entire cleaning process is carried out under a vacuum degree of less than 0.1 bar. The specific steps are as follows:

[0028] Flushing and soaking cleaning: The hot cleaning agent that has been finely filtered is filled into the working chamber from the cleaning agent storage tank. To improve the cleaning effect, optional material frame rotation / swing, cyclic pressure flushing or ultrasonic cleaning can be added. When the soaking is completed, the cleaning agent is returned to the cleaning agent storage tank through coarse filtration and fine filtration;

[0029] Steam degreasing: The cleaning agent vapor generated by the evaporator returns to the working chamber to remove grease on the workpiece. When the cleaning agent vapor completely covers the workpiece to be cleaned, the steam degreasing is completed;

[0030] Vacuum drying: vacuuming is used to enhance drying. After the extracted polluted cleaning agent mixed gas passes through the condenser, most of the pollutants are condensed and directly returned to the cleaning agent storage tank. Fresh air or nitrogen is used to rinse the working chamber. This step can ensure that the remaining cleaning agent traces after vacuum drying are completely removed from the working chamber.

[0031] The cleaning machine uses a dedicated tray. After the parts are loaded, they are sent to the closed cleaning chamber via automatic or unpowered roller conveyors. Other modules of the digital repair production line use AGV unmanned transport vehicles to deliver materials to the entrance. After personnel transfer the materials to the dedicated tray, cleaning work begins.

[0032] S003. Fault inspection work:

[0033] In response to the diverse requirements of workpieces, the external and internal dimensions of the workpieces are measured using an online three-coordinate automatic measuring machine, covering more than 90% of dimensional detection and achieving fully automated online detection. Temperature and humidity sensors monitor the room temperature and humidity to ensure the temperature and humidity during measurement, thereby ensuring measurement accuracy.

[0034] Programmable inspection systems and other inspection equipment can be used to perform other project fault inspections. At the same time, the measurement data can be automatically recorded in the digital process. When measuring unqualified workpieces, a dialog box will automatically pop up, and the operator can fill in the repair and treatment opinions after reviewing the measurement report;

[0035] A roller material line is set on the buffer station, which can be directly connected to the AGV. The AGV transfers the pallet to the roller material line. A blocking device is set on the buffer station to position the pallet. The buffer station is equipped with an active roller, which is connected to the automatic pallet transport line on the measuring machine table. The pallet can be transported to the three-coordinate automatic measuring machine table for positioning.

[0036] According to the type of parts provided, the corresponding table fixture is designed, and all workpiece fixtures are concentrated on two pallets, mainly including V-block support, expansion sleeve, and clamping type clamping methods;

[0037] Combined with the matrix measurement fixture, the clamping posture of the workpiece on the entire pallet is measured and simulated to confirm the clamping posture, stylus configuration and ultimately evaluate the overall measurement cycle of the workpiece on a pallet;

[0038] One pallet can meet the clamping requirements of more than 10 workpieces, ultimately achieving a complete set of parts clamping at one time, starting the three-dimensional coordinate measuring machine for automatic measurement at one time, and obtaining all measurement results at one time. The on-site dashboard displays the test results, and the program is packaged according to icons, allowing independent re-testing of individual parts.

[0039] The room is equipped with an observation window, through which the measurement process can be observed. Once an abnormality occurs, the measurement can be stopped in time to eliminate the fault;

[0040] S004. Repair work:

[0041] Before repair, place the part to be repaired on the workbench. Under the control of the software cabinet, the three-degree-of-freedom manipulator automatically clamps the part to the workpiece grinding table and repairs the surface to the required range.

[0042] Use an ultrasonic automatic quick-wash station to clean the grinding paste to ensure that the surface of the parts is clean and free of impurities. Use a roughness tester to check the surface roughness of the parts, and a flatness tester to check the flatness of the parts. After completion, the three-degree-of-freedom robot automatically clamps the parts to the qualified workbench to complete the grinding repair work;

[0043] S005, Automatic transfer work:

[0044] When the automatic transfer AGV arrives at the conveyor line and starts to deliver a pallet, it exchanges signals with the conveyor line's PLC. The conveyor line's PLC writes the pallet's status into a register. When the automatic transfer AGV arrives at the conveyor line position, it sends a status instruction. After the PLC reads the register's status, it gives a confirmation signal. When delivering a pallet, the conveyor line must be clear of occupied pallets. When receiving a pallet, the conveyor line must be clear of occupied pallets.

[0045] S006. Visual inspection work:

[0046] A camera is used to convert the detected target into an image signal, which is then transmitted to a dedicated image processing system and converted into a digital signal based on pixel distribution, brightness, color and other information.

[0047] The image processing system performs various operations on these signals to extract the characteristics of the target, such as area, number, position, and length, and then outputs the results based on the preset tolerances and other conditions, including size, angle, number, pass / fail, and presence / absence of categories, to achieve automatic recognition function;

[0048] S007, Warehouse work:

[0049] The warehouse is designed with pallet size, pallet bracket spacing, access port height, and access port size according to the storage material requirements and workshop space layout;

[0050] Designed in accordance with target production capacity requirements and in combination with the actual space dimensions of the workshop, the vertical storage racks are located on both sides of the stacker track, with the first and second rows of shelves arranged. Both sides can store large and small pallets respectively. Furthermore, based on the different types of materials stored, the storage area is further divided into parts storage area, shell storage area, overhaul pump storage area and faulty pump storage area.

[0051] S008, Assembly work:

[0052] When assembly is required, the pallet of a single plunger pump is delivered to the assembly station via a conveyor line. The visual inspection camera checks the completeness of the parts to determine whether the assembly conditions are met, and provides guidance and monitoring for the assembly process. Once qualified, the product housing is fixed to the positioner.

[0053] Use auxiliary workbenches to perform manual assembly of some small components, mainly for assembly and repair of small parts;

[0054] Use a spring press to measure spring force values, and use a servo press, servo electric cylinder, and tooling to perform automated auxiliary assembly work, primarily for housing mounting parts, including press-fitting and comprehensive assembly.

[0055] Use power-assisted spreaders to transfer large components and reduce labor intensity.

[0056] The related attachment information of step S001 is a two-dimensional process document and a three-dimensional assembly model class.

[0057] The external dimensions of the workpiece in step S003 include diameter, groove width and height, and total length, and the internal dimensions include hole diameter, hole depth, and step height.

[0058] The beneficial effects of the present invention are: the present invention improves the disadvantages of manual work, assists the manual repair process, forms modular processes and standards, standardizes the work process, and stabilizes product quality; standardizes the management of tooling, rationally arranges equipment and tooling, reduces the increase of non-value-added time, improves work efficiency, and reduces unnecessary time waste; reduces the manual collection of production data, improves production efficiency and reduces the probability of errors, and forms a suitable information feedback system. BRIEF DESCRIPTION OF THE DRAWINGS

[0059] The present invention will be further described below with reference to the accompanying drawings and examples.

[0060] Figure 1 It is a schematic diagram of the process structure of the present invention;

[0061] Figure 2 This is a schematic diagram of the overall layout of the present invention from a top view;

[0062] Figure 3 This is a schematic diagram of the partial three-dimensional structure of the decomposition and cleaning workstation of the present invention;

[0063] Figure 4 This is a schematic diagram of the three-dimensional structure of the fault detection workstation of the present invention;

[0064] Figure 5 This is a structural diagram of a repair workstation according to the present invention;

[0065] Figure 6 This is a schematic diagram of the storage structure of the present invention;

[0066] Figure 7 It is a structural schematic diagram of the assembly workstation of the present invention.

[0067] In the figure, 1. Disassembly and cleaning workstation; 2. Automatic cleaning workstation; 3. Fault detection workstation; 4. Repair workstation; 5. Assembly workstation; 6. Warehouse; 7. Visual inspection error-proofing camera; 8. Automatic transfer AGV; 9. Terminal equipment; 10. Dual-axis positioner; 11. Electric tightening spindle; 12. Single-axis positioner; 13. Servo tensioner and presser; 14. Disassembly tooling; 15. Ultrasonic cleaning machine; 16. Manual operation table; 17. Gas-liquid booster cylinder press; 18. Cache channel; 19. Controller; 20. Table fixture; 21. Cache station; 22. Automatic pallet transport line; 23. Three-coordinate automatic measuring machine; 24. Sensor. 25. Workbench for products to be repaired; 26. Roughness tester; 27. Flatness tester; 28. Ultrasonic automatic quick-washing station; 29. ​​Three-degree-of-freedom manipulator; 30. Workpiece grinding table; 31. Workbench for qualified products; 32. Software cabinet; 33. Vertical warehouse protective glass room; 34. Pneumatic lifting platform; 35. Manual and automatic conveyor line; 36. Automatic conveyor line; 37. Stacker; 38. First row of shelves; 39. Second row of shelves; 40. Servo press; 41. Servo electric push cylinder; 42. Visual inspection camera; 43. Conveyor line; 44. Auxiliary workbench; 45. Spring press; 46. Positioner; 47. Power-assisted hoist; 48. Tooling tools. DETAILED DESCRIPTION

[0068] In order to make the technical means, creative features, objectives and effects achieved by the present invention easier to understand, the present invention is further described below.

[0069] like Figures 1 to 7 As shown in the figure, a highly integrated aviation hydraulic piston pump repair line, based on the MES system, includes an automatic transfer AGV8, a storage warehouse 6, and also includes:

[0070] The disassembly and cleaning workstation 1, the automatic cleaning workstation 2, the fault inspection workstation 3, and the repair workstation 4 are respectively equipped with a buffer channel 18, and are transported between the storage warehouse 6 by automatic transfer AGV 8 or a combination of manual transfer;

[0071] Automatic cleaning workstation 2 is connected to the disassembly and cleaning workstation 1 through a bull's eye platform to perform fine cleaning on parts after rough disassembly and before assembly;

[0072] Assembly workstation 5: After all parts are assembled, they are transported via roller conveyor for assembly;

[0073] The storage warehouse 6 is directly connected to the assembly workstation 5 through a roller conveyor;

[0074] Visual inspection error-proofing camera 7 checks for missing parts against templates before storage and sends the results back to the MES system for requesting missing parts.

[0075] The present invention improves the disadvantages of manual work, assists the manual repair process, forms modular processes and standards, standardizes the work process, and stabilizes product quality; standardizes tool management, rationally arranges equipment and tooling, reduces the increase of non-value-added time, improves work efficiency, and reduces unnecessary time waste; reduces the manual collection of production data, improves production efficiency and reduces the probability of errors, and forms a suitable information feedback system.

[0076] When a hydraulic piston pump enters the repair process, it first enters disassembly and cleaning station 1 for disassembly down to the component level and preliminary ultrasonic cleaning. It then enters automated cleaning station 2 for precision cleaning, cleaning until the surface is clean, dry, and free of impurities. After cleaning, it is sent to fault inspection station 3 for part fault detection. Based on the fault inspection's conclusions, it enters repair station 4 for grinding, repair, and testing. After repairs, all parts are returned to storage warehouse 6 via automated transfer AGV 8. Before storage, visual inspection and error-proofing cameras 7 are used to check for missing parts against templates. The results are then transmitted to the MES system for requesting missing parts. After inspection, the parts enter storage warehouse 6 for assembly. Once all parts are complete, they are transported via roller conveyors to assembly station 5 for assembly. Once qualified, the repair line work is complete and the parts are sent for testing.

[0077] The decomposition and cleaning workstation 1 includes a terminal device 9 that transmits production task-related information to the production station in accordance with the process sequence, a dual-axis positioner 10 that automatically rotates to a suitable position according to the work step for easy decomposition, an electric tightening shaft 11 that automatically decomposes various fasteners, a single-axis positioner 12 for receiving the decomposed upper end cover, a servo puller and press 13 and a disassembly tool 14 that cooperate with pulling out internal parts to continue decomposition, a manual operating table 16 and a gas-liquid booster cylinder press 17 for decomposing partial assemblies, and an ultrasonic cleaning machine 15 for rough cleaning of workpieces.

[0078] By configuring a single-axis positioner 12, a double-axis positioner 10, a servo tensioner and presser 13 and other automated operating mechanisms, the disassembly operation is comprehensively assisted and supported. All tool racks have a full set of tools that meet the disassembly process, which are integrated and customized at appropriate locations in the workstation for easy access. The entire process of disassembly and ultrasonic rough cleaning of the plunger pump can be completed, and information and logistics docking with the warehousing system can be achieved.

[0079] The automatic cleaning workstation 2 operates in a vacuum-sealed working chamber by flushing and soaking, rotating and rocking parts, steam degreasing, and vacuum drying.

[0080] By analyzing the existing process flow, we identified practical requirements for improvement and developed technical specifications and requirements for the entire hydraulic piston pump repair unit. Incorporating advanced automation implementation experience from the industry, we replanned the existing workshop layout and configured various functional modules.

[0081] The fault inspection workstation 3 includes a controller 19 for executing system instructions, a table fixture 20 for clamping parts to ensure that the parts are fixed during measurement, a cache station 21 for temporarily storing parts to be measured, an automatic pallet transport line 22 for automatically transporting the temporarily stored parts into a constant temperature room for measurement, a three-coordinate automatic measuring machine 23 for directly measuring the size of parts, and a sensor 24 for measuring the temperature and humidity in the room for transmitting temperature and humidity data for room temperature and humidity control.

[0082] The repair workstation 4 includes a workbench 25 for placing parts to be repaired, a roughness detector 26 for checking the surface roughness of parts, a flatness detector 27 for checking the flatness of parts, an ultrasonic automatic quick washing table 28 for cleaning the grinding paste and ensuring that the surface of the parts is clean and free of impurities, a three-degree-of-freedom manipulator 29 for clamping parts, a workpiece grinding table 30 for repairing parts, a qualified product workbench 31 for placing qualified parts, and a software cabinet 32 ​​for implementing command control.

[0083] The assembly workstation 5 includes a servo press 40 and a servo electric push cylinder 41 for automated auxiliary assembly work, a visual inspection camera 42 for detecting the completeness of parts, a conveyor line 43 for automatically inputting part trays from the storage warehouse 6 into the assembly line, an auxiliary workbench 44 for assembly and repair of small parts, a spring press 45 for measuring spring force, a positioner 46 that automatically changes its posture to cooperate with the assembly movements of personnel, a power-assisted hoist 47 for transferring large parts, and a tooling tool 48 with the ability to meet the detection requirements of the assembly process.

[0084] The automation of the repair process provides an automated basis for cleaning, dimensional inspection, and grinding processes. All such processes adopt automated repair methods, which are in line with the latest developments in modern manufacturing technology, grinding technology, disk repair technology, detection technology, control technology, and computer technology, and have a high technical level.

[0085] The storage warehouse 6 includes a warehouse protective glass room 33, a pneumatic lifting platform 34 for temporary interception and visual photography identification, a manual and automatic conveyor line 35 for automatic conveyor line entry and docking with the entry conveyor line, an automatic conveyor line 36 for receiving pallets, a stacker 37 for conveying pallets, and a first row of shelves 38 and a second row of shelves 39 arranged on both sides of the stacker 37 track.

[0086] Materials are automatically transferred in before assembly and out after work is complete. The assembly process is checked step by step, with detailed instructions for each step. Advanced tools and gauges are rationally configured, and various tooling is designed and manufactured. These are organically integrated into the intelligent assembly workstation for quick access by operators, improving overall assembly quality and efficiency.

[0087] Record the completeness check after fault detection and before assembly, automatically identify missing parts with vision and feed back to MES to generate a missing parts catalog, visually check the correctness of parts, and prevent further assembly when completeness is not met or the parts are incorrect. Combined with the standardization of the process, parts are picked up one by one for assembly to prevent missing and wrong assembly.

[0088] A highly integrated method for using an aviation hydraulic plunger pump repair line, the specific steps are as follows:

[0089] S001. Decomposition and cleaning work:

[0090] After the production dispatch is completed through the MES system, the relevant information of the production task is transmitted to the terminal device 9 of the production station;

[0091] The worker can view the corresponding production task and related attachment information and production preparation information through the terminal device 9, and then click to receive the task instruction to start the attachment decomposition work;

[0092] According to the digital process flow of the product on the terminal device 9, the work content is prompted one by one. The workstation is equipped with semi-automatic clamping equipment and customized tool tables. After each decomposed process is completed, the system prompts the work content and required tools of the next process;

[0093] After the automatic transfer AGV8 transfers the pump material to be repaired to the disassembly station, the disassembly station lifts the workpiece, and the operator fixes the workpiece with the dual-axis positioner 10 and starts the disassembly work. The dual-axis positioner 10 automatically rotates to the appropriate position according to the work step to facilitate disassembly, and uses the electric tightening spindle 11 to automatically disassemble various fasteners;

[0094] The disassembled upper end cover is transferred to the single-axis positioner 12 and automatically rotated to the appropriate position. The servo puller and presser 13 and the disassembly tool 14 are used to pull out the internal parts and continue to disassemble. Some assemblies are disassembled using the manual operation table 16 and the gas-liquid booster cylinder press 17.

[0095] The disassembled parts are stored in a special material tray and can be easily transferred to the rough cleaning station on the non-powered material channel. The lifting platform descends and the workpiece is sent into the ultrasonic cleaning machine 15. After a period of rough cleaning, it rises and the parts are manually blown dry.

[0096] After the rough cleaning is completed, the parts are picked up manually and placed one by one in the material tray inside the buffer channel 18. After the rough cleaning, they can be directly put into storage or automatically cleaned. The disassembly process is carried out according to the single step of material inventory, and the specific operation content of each step is prompted according to the process of the terminal device 9;

[0097] After disassembly, the parts are placed in a dedicated cleaning box and transported to the cleaning area. Information data such as material anomalies during the disassembly process is uploaded through various means to form a complete digital disassembly process and achieve data traceability.

[0098] S002, automatic cleaning work:

[0099] The cleaning process is carried out under vacuum. Organic solvents or modified alcohols are used as cleaning media, and inorganic solvents can also be used as auxiliary agents. The entire cleaning process is carried out under a vacuum degree of less than 0.1 bar. The specific steps are as follows:

[0100] Flushing and soaking cleaning: The hot cleaning agent that has been finely filtered is filled into the working chamber from the cleaning agent storage tank. To improve the cleaning effect, optional material frame rotation / swing, cyclic pressure flushing or ultrasonic cleaning can be added. When the soaking is completed, the cleaning agent is returned to the cleaning agent storage tank through coarse filtration and fine filtration;

[0101] Steam degreasing: The cleaning agent vapor generated by the evaporator returns to the working chamber to remove grease on the workpiece. When the cleaning agent vapor completely covers the workpiece to be cleaned, the steam degreasing is completed;

[0102] Vacuum drying: vacuuming is used to enhance drying. After the extracted polluted cleaning agent mixed gas passes through the condenser, most of the pollutants are condensed and directly returned to the cleaning agent storage tank. Fresh air or nitrogen is used to rinse the working chamber. This step can ensure that the remaining cleaning agent traces after vacuum drying are completely removed from the working chamber.

[0103] The cleaning machine uses a dedicated tray. After the parts are loaded, they are sent to the closed cleaning chamber via automatic or unpowered roller conveyors. Other modules of the digital repair production line use AGV unmanned transport vehicles to deliver materials to the entrance. After personnel transfer the materials to the dedicated tray, cleaning work begins.

[0104] S003. Fault inspection work:

[0105] In response to the diverse requirements of workpieces, the external and internal dimensions of the workpieces are measured using an online three-dimensional automatic measuring machine 23, covering more than 90% of dimensional detection and achieving fully automated online detection. A temperature and humidity sensor 24 monitors the room temperature and humidity to ensure the temperature and humidity during measurement, thereby ensuring measurement accuracy.

[0106] Programmable inspection systems and other inspection equipment can be used to perform other project fault inspections. At the same time, the measurement data can be automatically recorded in the digital process. When measuring unqualified workpieces, a dialog box will automatically pop up, and the operator can fill in the repair and treatment opinions after reviewing the measurement report;

[0107] A roller material line is set on the buffer station 21, which can be directly connected to the AGV. The AGV transfers the pallet to the roller material line. A blocking device is set on the buffer station 21 to position the pallet. The buffer station 21 has its own active roller and connects to the pallet automatic transport line 22 on the measuring machine table. The pallet can be transported to the table of the three-dimensional automatic measuring machine 23 for positioning;

[0108] According to the provided part type, the corresponding table fixture 20 is designed, and all workpiece fixtures are concentrated on two pallets, mainly including V-block support, expansion sleeve, and clamping type clamping methods;

[0109] Combined with the matrix measurement fixture, the clamping posture of the workpiece on the entire pallet is measured and simulated to confirm the clamping posture, stylus configuration and ultimately evaluate the overall measurement cycle of the workpiece on a pallet;

[0110] One pallet can meet the clamping requirements of more than 10 workpieces, ultimately achieving a complete set of parts clamping at one time, starting the three-dimensional coordinate measuring machine 23 automatic measurement at one time, and obtaining all measurement results at one time. The on-site dashboard displays the test results, and the program is packaged according to icons, allowing independent re-testing of individual parts.

[0111] The room is equipped with an observation window, through which the measurement process can be observed. Once an abnormality occurs, the measurement can be stopped in time to eliminate the fault;

[0112] S004. Repair work:

[0113] Before repair, the part to be repaired is placed on the workbench 25. Under the control of the software cabinet 32, the three-degree-of-freedom manipulator 29 automatically clamps the part to the workpiece grinding table 30 and repairs the surface to the required range;

[0114] Use ultrasonic automatic quick washing station 28 to clean the grinding paste to ensure that the surface of the part is clean and free of impurities. Use roughness tester 26 to check the surface roughness of the part, and flatness tester 27 to check the flatness of the part. After completion, the three-degree-of-freedom manipulator 29 automatically clamps the part to the qualified product workbench 31 to complete the grinding repair work;

[0115] S005, Automatic transfer work:

[0116] When the automatic transfer AGV8 arrives at the conveyor line and starts to deliver the pallet, it exchanges signals with the PLC of the conveyor line. The PLC of the conveyor line writes the status of the pallet in the register. When the automatic transfer AGV8 arrives at the conveyor line position, it sends a status instruction. After the PLC reads the status of the register, it gives a confirmation signal. When delivering a pallet, there must be no pallet occupied on the conveyor line. When receiving a pallet, there must be a pallet on the conveyor line.

[0117] S006. Visual inspection work:

[0118] A camera is used to convert the detected target into an image signal, which is then transmitted to a dedicated image processing system and converted into a digital signal based on pixel distribution, brightness, color and other information.

[0119] The image processing system performs various operations on these signals to extract the characteristics of the target, such as area, number, position, and length, and then outputs the results based on the preset tolerances and other conditions, including size, angle, number, pass / fail, and presence / absence of categories, to achieve automatic recognition function;

[0120] S007, Warehouse work:

[0121] Warehouse 6 designs the pallet size, pallet bracket spacing, access port height, and access port size according to storage material requirements and workshop space layout;

[0122] Designed in accordance with target production capacity requirements and in combination with the actual space dimensions of the workshop, the vertical storage racks are located on both sides of the stacker crane 37 track, with the first row of shelves 38 and the second row of shelves 39 arranged. Both sides can store large and small pallets respectively. The storage area is further divided into parts storage area, shell storage area, overhaul pump storage area and faulty pump storage area according to the different types of materials stored.

[0123] S008, Assembly work:

[0124] When assembly is required, the pallet of a single plunger pump is delivered to the assembly station via the conveyor line 43. The visual inspection camera 42 checks the completeness of the parts, determines whether the assembly conditions are met, and guides and monitors the assembly content. If qualified, the product shell is fixed to the positioner 46.

[0125] Use the auxiliary workbench 44 to perform manual assembly of some small components, mainly for the assembly and repair of small parts;

[0126] Use a spring press 45 to measure the spring force value, and use a servo press 40, a servo electric push cylinder 41 and a tool 48 to perform automated auxiliary assembly work, mainly operating on housing mounting parts, including press fitting and comprehensive assembly;

[0127] The use of a power-assisted spreader 47 for transferring large components reduces labor intensity.

[0128] The related attachment information of step S001 is a two-dimensional process document and a three-dimensional assembly model class.

[0129] Step S001 requires a reserved entrance to the automatic cleaning machine to achieve integrated disassembly and automatic cleaning. The production line reserves the corresponding software interface to facilitate the subsequent integration with digital processes and intelligent production line upgrades.

[0130] The disassembly station is rationally equipped with various advanced tools, and various tooling is designed and manufactured. These tools are organically combined in the intelligent disassembly workstation for operators to quickly access, thereby improving the overall disassembly quality and efficiency.

[0131] The cleaning station consists of a manual cleaning area and an automated cleaning area. The manual cleaning area and the decomposition area are connected by a conveyor line. The automated cleaning area is equipped with an ultrasonic cleaning station for rough cleaning of parts, while retaining the traditional cleaning mode of manual fine cleaning. A reserved outlet in the manual cleaning area connects to the automated cleaning area for equipment fine cleaning. After the parts are rough cleaned in the ultrasonic cleaning station, the fine cleaning method is manually selected through a two-way channel. After manual fine cleaning, the parts can be cached online and then boxed and stored after drying.

[0132] After disassembly, parts are placed in a dedicated cleaning box and transported to the cleaning area. Data on material anomalies and other information during the disassembly process is uploaded through various means, forming a complete digital disassembly process and achieving data traceability.

[0133] The automatic cleaning work in step S002 is an indispensable step in the repair and manufacturing process for cleaning parts. The existing process mainly uses organic detergents to manually clean each part, which is inefficient and the cleaning effect varies from person to person.

[0134] The automated cleaning station is used for fine cleaning of parts, suitable for the delicate cleaning of parts after rough disassembly and prior to assembly. A dedicated filtration system and other optional modules are selected based on analysis of the actual cleaning conditions. A hydrocarbon-based cleaning agent is used, characterized by high cleaning efficiency, minimal volatile losses, non-toxicity, excellent material compatibility, and reasonable cost. The cleaning machine can be equipped with different module configurations, making it suitable not only for degreasing and emulsifying mass-produced parts, but also for the delicate cleaning of assembled parts. It can remove debris from mass-produced parts and, during the delicate cleaning process, remove particles within a specified size.

[0135] The external dimensions of the workpiece in step S003 include diameter, groove width and height, and total length, and the internal dimensions include hole diameter, hole depth, and step height.

[0136] Step S004 integrates single-plane large-scale part grinding, simultaneous grinding of multiple small-scale parts, intelligent flatness detection and analysis, intelligent roughness detection and analysis, and ultrasonic cleaning and quick-drying functions. The entire intelligent grinding system utilizes PLC control to implement feedback control for workpiece flatness detection, grinding, cleaning and drying, and secondary flatness detection and judgment. The system also features built-in grinding disc detection and self-repair capabilities, equipped with a digital large-scale flatness detector and an automatic disc repair device.

[0137] Grinding inspection is precise and intuitive, integrating self-testing, repairing, and self-cleaning, all in a fully automated process. The system's operating process is displayed in real time, and the system's process control software and flatness inspection software are mutually supportive and independent, enabling independent transmission and output of inspection data. A universal interface is also reserved for later data interconnection.

[0138] All the parts to be repaired, ground and inspected are placed on the workbench 25, and the software cabinet 32 ​​instructs the three-degree-of-freedom manipulator 29 to grab them according to the compiled program instructions.

[0139] The vertical warehouse sealing treatment in step S007 is as follows: an independent vertical warehouse protective glass room 33 is formed by using organic glass + aluminum alloy frame profiles on the upper, left, right, front and back sides of the vertical warehouse, and doors are opened on the left and right sides of the vertical warehouse protective glass room 33, and personnel can enter and exit through the doors on the left and right sides.

[0140] In step S008, the operator performs step-by-step operations according to the digital process instructions. The servo press 40 is manually operated, and the torque gun operates automatically to reach the preset torque, which is completed automatically.

[0141] The visual inspection camera 42 will perform a fully automatic inspection after the tray is in place, automatically determining whether there are products in the tray and how many products there are.

[0142] The positioner 46 automatically changes its posture according to the process to cooperate with the assembly action of the personnel. When the assembly is completed or not, according to the instructions, the product and the pallet are automatically transferred to the vertical warehouse through the conveyor line 43 for storage.

[0143] Material information, measurement parameters, repair and test data in the assembly process are uploaded through various means to form a complete digital assembly process and achieve data traceability.

[0144] It can realize pallet storage, parts assembly, visual inspection camera 42, conveyor line 43 work area and offline workbench work area during the processing of old parts; the visual inspection camera 42 has the function of detecting whether the incoming parts to be assembled match the MES system, including old parts and plunger pump parts, and has the function of rechecking whether the rubber ring is installed correctly, including the position and color; it has a detection tool 48 that meets the requirements of the assembly process. The tool is easy to disassemble and assemble, the measuring tool is simple, and the measurement data can be transmitted to the system in real time; there is an RFID reading device in and out of the workstation.

[0145] The basic principles, main features, and advantages of the present invention are shown and described above. Those skilled in the art should understand that the present invention is not limited to the foregoing embodiments. The foregoing embodiments and description merely illustrate the principles of the present invention. Various changes and modifications may be made to the present invention without departing from the spirit and scope of the present invention. Such changes and modifications are intended to fall within the scope of the present invention. The scope of protection claimed in the present invention is defined by the appended claims and their equivalents.

Claims

1. A method for using a highly integrated aviation hydraulic plunger pump repair line, wherein the highly integrated aviation hydraulic plunger pump repair line is based on an MES system and includes an automatic transfer AGV (8), a storage vertical warehouse (6), and further includes: The disassembly and cleaning workstation (1), the automatic cleaning workstation (2), the fault inspection workstation (3), and the repair workstation (4) are respectively equipped with a buffer channel (18), and are transported between the storage warehouse (6) by an automatic transfer AGV (8) or a combination of manual transfer; The automatic cleaning workstation (2) is connected to the decomposition cleaning workstation (1) via a bull's eye platform, and performs fine cleaning on the parts after rough decomposition cleaning and before assembly; Assembly workstation (5), after all parts are assembled, they are transported via roller conveyor for assembly work; The storage warehouse (6) is directly connected to the assembly workstation (5) via a roller conveyor; Visual inspection error-proofing camera (7) checks for missing parts against templates before storage and sends the results back to the MES system for requesting missing parts; The decomposition and cleaning workstation (1) includes a terminal device (9) for transmitting production task related information to the production station according to the process sequence, a double-axis positioner (10) that automatically rotates to a suitable position according to the process step for easy decomposition, an electric tightening shaft (11) that automatically decomposes various fasteners, a single-axis positioner (12) for receiving the decomposed upper end cover, a servo puller (13) and a disassembly tool (14) for pulling out internal parts to continue decomposition, a manual operating table (16) and a gas-liquid booster cylinder press (17) for decomposing some assemblies, and a power supply unit (11) for the decomposition of the components. The ultrasonic cleaning machine (15) for rough cleaning of the workpiece; the fault inspection workstation (3) includes a controller (19) for executing system instructions, a table fixture (20) for clamping the parts to ensure the fixed state of the parts during measurement, a cache station (21) for temporarily storing the parts to be measured, an automatic pallet transport line (22) for automatically transporting the temporarily stored parts to the constant temperature room for measurement, a three-coordinate automatic measuring machine (23) for directly measuring the size of the parts, and a sensor (24) for measuring the temperature and humidity in the room for transmitting temperature and humidity data to control the temperature and humidity of the room; the The repair workstation (4) includes a workbench (25) for placing parts to be repaired, a roughness detector (26) for checking the surface roughness of parts, a flatness detector (27) for checking the flatness of parts, an ultrasonic automatic quick-washing table (28) for cleaning the grinding paste and ensuring that the surface of the parts is clean and free of impurities, a three-degree-of-freedom manipulator (29) for clamping parts, a workpiece grinding table (30) for repairing parts, a qualified workbench (31) for placing qualified parts, and a software cabinet (32) for realizing command control; the assembly workstation (5) It includes a servo press (40) and a servo electric push cylinder (41) for performing automated auxiliary assembly work, a visual inspection camera (42) for detecting the completeness of parts, a conveyor line (43) for automatically inputting part trays from a storage warehouse (6) to an assembly line, an auxiliary workbench (44) for assembling and repairing small parts, a spring press (45) for measuring spring force, a positioner (46) that automatically changes its posture to coordinate with the assembly movements of personnel, a power-assisted hoist (47) for transferring large parts, and a tooling tool (48) capable of detecting and meeting the requirements of the assembly process. The characteristics are as follows: the specific steps of using the method are as follows: S001. Decomposition and cleaning work: After the production dispatch is completed through the MES system, the relevant information of the production task is transmitted to the terminal equipment of the production station (9); Workers can view the corresponding production tasks and related attachment information and production preparation information through the terminal device (9), and then click to receive the task instructions and start the attachment decomposition work; According to the digital process flow of the product on the terminal device (9), the work content is prompted one by one. The workstation is equipped with semi-automatic clamping equipment and customized tool tables. The system prompts the work content and required tools of the next process; After the automatic transfer AGV (8) transfers the pump material to be repaired to the disassembly station, the disassembly station lifts the workpiece, and the operator fixes the workpiece with the double-axis positioner (10) and starts the disassembly work. The double-axis positioner (10) automatically rotates to a suitable position according to the work step to facilitate disassembly, and uses the electric tightening shaft (11) to automatically disassemble various fasteners; The disassembled upper end cover is transferred to a single-axis positioner (12) and automatically rotated to a suitable position. The internal parts are pulled out using a servo puller (13) and a disassembly tool (14) to continue disassembly. Some assemblies are disassembled using a manual operating table (16) and a gas-liquid booster cylinder press (17). The disassembled parts are stored in a special material tray and can be easily transferred to the rough cleaning station on the non-powered material channel. The lifting platform descends and the workpiece is sent into the ultrasonic cleaning machine (15). After a period of rough cleaning, it rises and the parts are manually blown dry. After the rough cleaning is completed, the parts are picked up manually and placed one by one in the material tray inside the buffer channel (18). After the rough cleaning, they can be directly put into storage or automatically cleaned. The disassembly process is carried out according to the material inventory of each step, and the specific operation content of each step is prompted according to the process of the terminal device (9); After disassembly, the parts are placed in a special cleaning box and transported to the cleaning area. During the disassembly process, the abnormal information data of the materials are uploaded through various means to form a complete digital disassembly process. S002, automatic cleaning work: The cleaning process is carried out under vacuum. The cleaning medium is an organic solvent or modified alcohol, and an inorganic solvent can also be used as an auxiliary. The entire cleaning process is carried out under a vacuum degree of less than 0.1 bar. The specific steps are as follows: Flushing and soaking cleaning: The hot cleaning agent that has been finely filtered is filled into the working chamber from the cleaning agent storage tank; Steam degreasing: The cleaning agent vapor generated by the evaporator returns to the working chamber to remove grease on the workpiece; when the cleaning agent vapor completely covers the workpiece to be cleaned, the steam degreasing is completed; Vacuum drying: vacuum is used to enhance drying. After the extracted polluted cleaning agent mixed gas passes through the condenser, most of the pollutants are condensed and directly returned to the cleaning agent storage tank. Fresh air or nitrogen is used to rinse the working chamber. The cleaning machine uses a dedicated material tray, which is fed into a closed cleaning chamber via an automatic or unpowered roller conveyor. Other modules of the digital repair production line use AGV unmanned transport vehicles to deliver materials to the entrance. After personnel transfer the materials to the dedicated material tray, they begin cleaning. S003. Fault inspection work: According to the requirements of multiple varieties of workpieces, the external and internal dimensions of the workpieces are measured by an online three-coordinate automatic measuring machine (23); the room temperature and humidity are monitored by a temperature and humidity sensor (24); Programmable detection system detection equipment can be used to detect other items, and the measurement data can be automatically recorded in the digital process; A roller material line is provided on the cache station (21) and can be directly connected to the AGV. The AGV transfers the pallet to the roller material line. A blocking device is provided on the cache station (21) to position the pallet. The cache station (21) has its own active roller and is connected to the pallet automatic transport line (22) on the measuring machine table. The pallet can be transported to the table of the three-coordinate automatic measuring machine (23) for positioning. According to the provided part type, the corresponding table fixture (20) is designed to concentrate all workpiece fixtures on two pallets; Combined with the matrix measurement fixture, the clamping posture of the workpiece on the entire pallet is measured and simulated to confirm the clamping posture, stylus configuration and ultimately evaluate the overall measurement cycle of the workpiece on a pallet; One pallet can meet the clamping requirements of more than 10 workpieces, and ultimately achieve a complete set of parts clamping at one time, start the three-coordinate automatic measuring machine (23) automatically for measurement, and obtain all measurement results at one time; the on-site board implements the display of the test results, and the program is packaged according to the icon, which can independently re-measure a single part; S004. Repair work: Before repair, the part to be repaired is placed on the workbench (25) to be repaired. Through the control of the software cabinet (32), the three-degree-of-freedom manipulator (29) automatically clamps the part to the workpiece grinding table (30) to repair the plane to the required range; The grinding paste is cleaned with an ultrasonic automatic quick washing table (28), and the surface roughness of the parts is checked with a roughness tester (26), and the flatness of the parts is checked with a flatness tester (27). After completion, the three-degree-of-freedom manipulator (29) automatically clamps the parts to the qualified product workbench (31), completing the grinding repair work; S005, Automatic transfer work: When the automatic transfer AGV (8) arrives at the conveyor line and starts to transport the pallet, it exchanges signals with the PLC of the conveyor line. The PLC of the conveyor line writes the status of the pallet in the register. When the automatic transfer AGV (8) arrives at the conveyor line position, it sends a status instruction. After the PLC reads the status of the register, it gives a confirmation signal. When delivering a pallet, the conveyor line must be free of pallets, and when receiving a pallet, the conveyor line must be occupied by a pallet. S006. Visual inspection work: A camera is used to convert the detected target into an image signal, which is then transmitted to a dedicated image processing system and converted into a digital signal based on pixel distribution, brightness, and color information. The image processing system performs various operations on these signals to extract the characteristics of the target, such as area, quantity, position, and length, and then outputs the results based on the preset tolerances and other conditions, including size, angle, number, pass / fail, and presence / absence; S007, Warehouse work: Warehouse (6) Design the pallet size, pallet bracket spacing, access port height, and access port size according to the storage material requirements and workshop space layout; S008, Assembly work: When assembly is required, the pallet of a single plunger pump is delivered to the assembly station via the conveyor line (43). The visual inspection camera (42) detects the completeness of the parts, determines whether the assembly conditions are met, and guides and monitors the assembly content. After passing the inspection, the product shell is fixed to the positioner (46).

2. The method for using a highly integrated aviation hydraulic plunger pump repair line according to claim 1, characterized in that: The automatic cleaning workstation (2) operates in a vacuum-sealed working chamber by flushing and soaking, rotating and swinging parts, steam degreasing, and vacuum drying.

3. The method for using a highly integrated aviation hydraulic plunger pump repair line according to claim 1, characterized in that: The storage vertical warehouse (6) includes a vertical warehouse protective glass room (33), a pneumatic lifting platform (34) for temporary interception and visual photo identification, a manual and automatic conveyor line (35) for automatic conveyor line entry and docking with the entry conveyor line, an automatic conveyor line (36) for receiving pallets, a stacker (37) for conveying pallets, and a first row of shelves (38) and a second row of shelves (39) arranged on both sides of the stacker (37) track.

4. The method for using a highly integrated aviation hydraulic plunger pump repair line according to claim 1, characterized in that: The relevant attachment information of step S001 is a two-dimensional process document and a three-dimensional assembly model.

5. The method for using a highly integrated aviation hydraulic plunger pump repair line according to claim 1, characterized in that: The external dimensions of the workpiece in step S003 include diameter, groove width and height, and total length, and the internal dimensions include hole diameter, hole depth, and step height.

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