A method for producing a bevel gear forging blank

Abstract

The present application relates to a kind of bevel gear forging blank production method, comprising the following steps: (1) first cut good forging by feeding mechanism into forging heating furnace and heat;(2) the temperature of the forging sent from forging heating furnace is detected, and the forging of 1200 DEG C is sent into forging forming machine and is beaten into hollow circular table shape;Forging that cannot reach 1200 DEG C is rejected;(3) hollow circular table shape after cooling The forging is sent into eddy current machine and is detected by eddy current, then sent into magnetic detection device and is detected by electromagnetic, and the hollow circular table shape of defective forging is rejected;(4) the hollow circular table shape of electromagnetic detection after no defect is demagnetized, and sent into workpiece rust-proof spraying device and is treated by rust-proof;(5) the hollow circular table shape after rust-proof treatment is sent into heat treatment furnace in batches and is treated by heat treatment, and the holding temperature of heat treatment is controlled at 935~940 DEG C, and the workpiece after heat treatment cooling is bevel gear forging. By the method, it helps to avoid that the bevel gear forging blank with metal defect flows into subsequent processing technology.

Description

Technical Field

[0001] This invention relates to a method for producing bevel gear forging blanks. Background Technology

[0002] In the production of bevel gear forgings, the blanks are made by heating bar-shaped steel in a forging furnace before further forging. The forging material is typically fed into the furnace manually onto a receiving plate, then pushed into the furnace by a pusher. During this process, for each piece of forging fed into the furnace, the worker must place the next piece onto the receiving plate, resulting in high workload. Furthermore, due to forging process requirements, the forging material generally needs to reach a certain temperature (e.g., above 1200 degrees Celsius) before being fed into subsequent forging equipment. However, the forging output from existing forging furnaces sometimes fails to reach the required temperature. Forgings that do not meet the temperature requirements will result in finished products that do not meet the process specifications if fed into the forging equipment.

[0003] Because bevel gear forgings often contain internal defects during the forging process, eddy current testing combined with magnetic probing is typically used to inspect the workpieces. However, the current method usually involves manually operating an eddy current machine for eddy current testing, then conveying the workpiece to a magnetic probing chamber via a conveyor belt. The workpiece is then manually immersed in magnetic probing fluid, and finally magnetized using a magnetic field transmitter. After inspection, good products are demagnetized. However, manually immersing and magnetizing the workpiece in magnetic probing fluid is inefficient, slows down the overall production schedule, and is labor-intensive due to mass production.

[0004] Furthermore, billets after magnetic detection are generally treated with rust prevention, typically by spraying rust-inhibiting liquid onto the workpiece surface. However, while existing rust-inhibiting machines spray rust-inhibiting liquid onto both the top and bottom surfaces of the workpiece, they only have a single air duct, which cannot guarantee that all the rust-inhibiting liquid on the workpiece surface, especially the bottom surface, will be blown off. Additionally, although the rust-inhibiting liquid is recycled, it is not filtered, easily causing blockage of the spray pipe. To improve the strength of the subsequently formed bevel gears, heat treatment is usually performed. However, the surface temperature of the workpiece is very high after heat treatment, requiring cooling before transfer to the next stage. Existing air-cooling devices are poorly designed, resulting in air entering the heat treatment machine and causing poor workpiece surface quality. Moreover, air cooling alone has low efficiency, and the output guide rack is not adjustable, making material handling inconvenient. Summary of the Invention

[0005] The purpose of this invention is to provide a method for producing bevel gear forging blanks, which helps to prevent bevel gear forging blanks with metal defects from entering subsequent processing and improves overall production efficiency.

[0006] The technical solution of the present invention is: a method for producing a bevel gear forging blank, comprising the following steps:

[0007] (1) First, the cut forging material is fed into the forging heating furnace through the feeding mechanism for heating;

[0008] (2) The temperature of the forging material sent from the forging heating furnace is tested. Forging materials that reach 1200°C are sent into the forging forming machine and forged into a hollow frustum shape; forging materials that cannot reach 1200°C are rejected.

[0009] (3) The cooled hollow frustum-shaped forgings are sent to an eddy current machine for eddy current testing, and then sent to a magnetic detection device for electromagnetic flaw detection to remove defective hollow frustum-shaped forgings.

[0010] (4) Demagnetize the hollow frustum-shaped forgings that have no defects after electromagnetic flaw detection and send them into the workpiece anti-rust spraying device for anti-rust treatment.

[0011] (5) After rust prevention treatment, the hollow frustum-shaped forgings are sent in batches to the heat treatment furnace for heat treatment. The heat treatment holding temperature is controlled at 935~940℃. The workpiece after heat treatment and cooling is the bevel gear forging.

[0012] Furthermore, the feeding mechanism includes an inclined material support plate, with a gantry spanning the lower part of the material support plate, and an elastic buffer plate fixed obliquely on the lower side of the gantry; a material blocking mechanism is provided at the lower part of the material support plate and in front of the gantry, and a V-shaped receiving plate is provided at the lower front end of the material support plate; one side of the receiving plate is connected to the forging heating furnace, and a pushing mechanism for pushing the forging into the forging heating furnace is provided on the other side of the receiving plate.

[0013] Furthermore, a fixed baffle is provided on one side of the material support plate, and an adjusting baffle is placed on the material support plate. The adjusting baffle is provided with a pair of adjusting grooves, and the adjusting baffle is connected and fastened to the material support plate by fastening bolts passing through the adjusting grooves. The material feeding mechanism includes a slot arranged horizontally at the lower part of the material support plate. A rotating plate with a semi-circular cross-section is arranged horizontally in the slot. The two ends of the rotating plate are rotatably connected to the material support plate. A baffle is fixed horizontally on the plane of the rotating plate. A drive mechanism for driving the rotating plate to rotate forward and backward is provided on the lower side of the material support plate.

[0014] Further, in step (2), qualified forgings are fed into the forging machine and scrap is kicked out by the forging material conveying device. The forging material conveying device includes a chain conveyor belt arranged horizontally and connected to the output end of the forging heating furnace. A temperature probe is provided on the upper side of the output end of the conveyor belt. An inclined discharge chute is provided on the output end side of the conveyor belt. A scrap kicking mechanism is provided on the discharge chute. An inclined material distribution chute is connected to the lower end of the discharge chute. The material distribution chute is connected to a first conveying channel and a second conveying channel respectively for sending forgings to the forging machine. A material distribution baffle is provided in the material distribution chute for allowing the forgings to enter the first conveying channel or the second conveying channel.

[0015] Furthermore, the waste removal mechanism includes gates on both side plates of the discharge chute, with downwardly inclined guide plates connected to the gates. The lower end of the guide plates is connected to a vertically arranged waste discharge pipe, and a receiving basket is provided at the lower end of the waste discharge pipe. A material distribution guide plate with its lower part rotatably connected to the discharge chute is installed on the gates, and a first driving mechanism is provided on the lower side of the discharge chute to drive the material distribution guide plate to swing towards another material distribution guide plate to divert the forging material into the guide plate.

[0016] Furthermore, the first conveying channel spirals downwards, and a receiving platform located on one side of the forging machine is connected to the output end of the first and second conveying channels.

[0017] Further, in step (3), the hollow frustum-shaped forging after eddy current detection is conveyed to the transition conveyor belt and fed into the loading conveyor belt of the magnetic detection device by the robot arm. The input end of the loading conveyor belt is equipped with a magnetic detection spraying mechanism, and the bottom of the loading conveyor belt is equipped with a magnetic field transmitting device. The loading conveyor belt includes a housing, and a number of guide rollers are rotatably connected at intervals along the conveying direction inside the housing. Sprockets are installed at both ends of the guide rollers. The sprockets on the same side of each guide roller are connected by chains. A number of conveying plates are spaced apart between the two chains along the movement direction of the chains. Workpiece limiting structures are symmetrically arranged on the left and right sides of the conveying plates.

[0018] Furthermore, the magnetic flux coating mechanism includes a storage tank located beside the housing, which stores magnetic flux. The housing at the input end of the feeding conveyor belt is provided with two upward-facing nozzles corresponding to the bottom of the workpiece. The upward-facing nozzles are connected to the storage tank via a parallel pipe with a water pump. The middle of the feeding conveyor belt is provided with two downward-facing spray nozzles corresponding to the top surface of the workpiece. The spray nozzles are connected to the storage tank via a parallel pipe with a water pump. The bottom of the housing is provided with a tray for receiving the falling magnetic flux, and the tray is connected to the storage tank via a pipe with a water pump.

[0019] Furthermore, the workpiece anti-rust spraying device includes a housing, a demagnetizer is installed at the feed inlet of the housing, a mesh conveyor belt with both ends extending out of the housing is arranged horizontally inside the housing, and anti-rust spraying pipes are arranged longitudinally on the upper and lower sides of the mesh conveyor belt inside the housing near the feed inlet. A blowing assembly is arranged inside the housing on the upper and lower sides of the mesh conveyor belt and on the rear side of the anti-rust spraying pipes. The blowing assembly includes a first blowing trough arranged longitudinally inside the housing and on the upper side of the mesh conveyor belt, with the air outlet of the first blowing trough facing downward. A second blowing trough with the air outlet facing upward is arranged below and on the rear side of the first blowing trough. A third blowing trough with the air outlet facing downward is also arranged above the discharge outlet of the housing.

[0020] Furthermore, a circulating cooling device is connected to the outlet of the heat treatment furnace. The circulating cooling device includes a heat dissipation channel. A conveyor belt is installed in the heat dissipation channel and is connected to the discharge port of the heat treatment machine. The conveyor belt extends out of the heat dissipation channel. An air cooling mechanism is installed on the heat dissipation channel. A circulating water cooling mechanism is installed in the heat dissipation channel. A receiving mechanism is installed at the outlet of the heat dissipation channel and is connected to the output end of the conveyor belt.

[0021] Compared with the prior art, the present invention has the following advantages:

[0022] 1. This method helps prevent defective bevel gear forgings from entering subsequent processing steps and improves overall production efficiency. It also facilitates individual forging loading, avoiding the need for workers to place each forging on the receiving plate after it has been loaded, thus reducing labor intensity.

[0023] 2. Removing forgings that do not reach the required temperature using a forging conveyor helps reduce the number of blanks with metal defects. Spraying and magnetizing with magnetic flux reduces manual labor, improves production efficiency, facilitates specialized production, and prevents defective blanks from flowing into subsequent turning processes.

[0024] 3. The workpiece anti-rust spraying device helps to prevent rust on both the upper and lower surfaces of the workpiece. Multiple air blowing channels remove excess anti-rust liquid from the workpiece, preventing excessive residue after treatment. It also facilitates the recycling and reuse of the anti-rust liquid.

[0025] 4. A circulating cooling system helps improve the cooling efficiency of the blank, thereby increasing production efficiency. Attached Figure Description

[0026] Figure 1 This is a flowchart of the present invention;

[0027] Figure 2 This is a schematic diagram of the feeding mechanism of the present invention;

[0028] Figure 3 For the present invention Figure 2 AA section view;

[0029] Figure 4 For the present invention Figure 3 Enlarged view of area B;

[0030] Figure 5 This is a schematic diagram of the structure of the rotating plate after it has been flipped.

[0031] Figure 6 This is a top view schematic diagram of the forging conveying device of the present invention;

[0032] Figure 7 For the present invention Figure 6 AA section view;

[0033] Figure 8 This is a bottom view of the first drive mechanism of the present invention;

[0034] Figure 9 For the present invention Figure 6 Enlarged view of area B;

[0035] Figure 10 For the present invention Figure 7 Enlarged view of area C;

[0036] Figure 11 This is a schematic diagram of the magnetic detection device of the present invention;

[0037] Figure 12 For the present invention Figure 11 Enlarged structural diagram at point A in the middle;

[0038] Figure 13 For the present invention Figure 11 Schematic diagram of the structure in the B-direction view;

[0039] Figure 14 This is a schematic diagram of the transition conveyor belt structure of the present invention;

[0040] Figure 15 This is a schematic diagram of the output conveyor belt structure of the present invention;

[0041] Figure 16 This is a schematic diagram of the workpiece anti-rust spraying device of the present invention;

[0042] Figure 17 This is a schematic diagram of the supply structure of the spray pipe of the present invention;

[0043] Figure 18 For the present invention Figure 16 A schematic diagram of direction A.

[0044] Figure 19 This is a schematic diagram of the circulating cooling device of the present invention;

[0045] Figure 20 This is a side view of the circulating cooling device after the material receiving mechanism has been removed according to the present invention. Detailed Implementation

[0046] To make the above features and advantages of the present invention more readily understood, specific embodiments are described below in conjunction with the accompanying drawings, but the present invention is not limited thereto.

[0047] refer to Figures 1 to 20

[0048] A method for producing a bevel gear forging blank includes the following steps:

[0049] (1) First, the cut forging material 1 is fed into the forging heating furnace A40 through the feeding mechanism for heating;

[0050] (2) The temperature of the forging material sent from the forging heating furnace is detected. If the output forging temperature reaches 1200℃, it is sent to the forging forming machine through the forging conveying device and forged into a hollow frustum shape. The forging forming machine is existing equipment. If the output forging temperature does not reach 1200℃, it is rejected through the forging conveying device. This effectively avoids the increased probability of defects in the formed hollow frustum forging due to insufficient temperature.

[0051] (3) The cooled hollow frustum-shaped forgings are sent to the eddy current machine C1 for eddy current testing. The eddy current machine is an existing technology product. Hollow frustum-shaped forgings that appear during the testing are removed. After that, hollow frustum-shaped forgings that pass the eddy current test are sent to the magnetic detection device for electromagnetic flaw detection. Defective hollow frustum-shaped forgings are removed.

[0052] (4) The hollow frustum-shaped forgings that have no defects after electromagnetic flaw detection are demagnetized by a demagnetizer C32, which is an existing technology equipment; and then sent to a workpiece anti-rust spraying device for anti-rust treatment.

[0053] (5) In order to improve the strength of the forging, the hollow frustum-shaped forgings after rust prevention treatment are sent in batches to heat treatment furnace E1 for heat treatment. The heat treatment holding temperature is controlled at 935~940℃. The workpiece after heat treatment and cooling is the bevel gear forging blank.

[0054] In this embodiment, the feeding mechanism includes an inclined support plate A10, with a gantry A26 horizontally spanning the lower part of the support plate. An inclined, elastic buffer plate A27 is fixed to the lower side of the gantry. A material-blocking mechanism A20 is located at the lower part of the support plate and in front of the gantry. A V-shaped receiving plate A30 is located at the lower front end of the support plate. Since the forging material is cylindrical, the V-shaped receiving plate prevents the forging material from rolling and positions it. One end of the receiving plate is connected to the inlet A41 of the forging heating furnace A40. A pushing mechanism A50 is located on the other side of the receiving plate to push the forging material into the forging heating furnace.

[0055] In this embodiment, in order to meet the needs of conveying forgings of different lengths, a fixed baffle A11 is provided on one side of the support plate, an adjusting baffle A12 is placed on the support plate, and a pair of adjusting grooves A13 are provided on the adjusting baffle. Fastening bolts A14 connected to the support plate are installed in the adjusting grooves, so that after the position of the adjusting baffle is adjusted, the connection and fastening between the adjusting baffle and the support plate is completed by the fastening bolts.

[0056] In this embodiment, to achieve sequential feeding of forgings, the feeding mechanism includes a slot A21 horizontally disposed at the lower part of the support plate. A rotating plate A22 with a semi-circular cross-section is horizontally disposed within the slot. Both ends of the rotating plate are rotatably connected to the support plate. A baffle A23 is horizontally fixed on the plane (plane containing the diameter) of the rotating plate, and the baffle can coincide with the axial direction of the rotating plate. A drive mechanism for driving the rotating plate to rotate in both directions is disposed on the lower side of the support plate, thereby driving the rotating plate to rotate and achieving the feeding and blocking actions.

[0057] In this embodiment, the driving mechanism includes a connecting rod A24 fixed to the arc surface of the rotating plate. The connecting rod is hinged to the telescopic rod of a driving cylinder A25. The housing of the driving cylinder is hinged to the bottom plate of the material support plate, thereby driving the rotating plate to rotate. The driving cylinder can also be an electric cylinder or a pneumatic cylinder.

[0058] In this embodiment, the lower end of the buffer plate is arc-shaped and is used to contact the upper end of the arc-shaped surface of the second forging, preventing the second forging from rolling directly downwards when the foremost forging rolls down. Since the buffer plate is a thin metal plate with a certain degree of elasticity, when the rotating plate rotates, the buffer plate prevents the second forging from rolling directly downwards. After the foremost forging leaves the baffle, the second forging rolls downwards and leaves the buffer plate under the action of gravity and the thrust of the subsequent forgings, so as to contact the arc-shaped surface of the rotating plate. It then contacts the baffle after the rotating plate rotates 90° counterclockwise.

[0059] In this embodiment, in order to push the forging into the forging heating furnace, the pushing mechanism includes a horizontally arranged pushing cylinder A51, and a pushing block A52 located on the upper side of the receiving plate is fixed to the end of the telescopic rod of the pushing rod. In order to prevent the forging from rolling onto the receiving plate and detaching from the receiving plate due to excessive speed, the front side of the receiving plate away from the receiving plate is also vertically provided with an anti-detachment baffle A31, so as to block the forging that has detached from the receiving plate back onto the receiving plate.

[0060] In its initial state, the baffle of the feeding mechanism is vertical, meaning the plane of the rotating plate is flush with the surface of the receiving plate. Forgings are manually placed on the receiving plate, with their circular surfaces in contact. At this point, the forging at the front (the first forging) is in contact with the baffle. When feeding is needed, the rotating plate is driven to rotate 90° clockwise, causing the forging at the front to roll down onto the receiving plate. At this point, half of the rotating plate's arc rotates to the upper side of the receiving plate, blocking the next forging. Then, the rotating plate rotates 90° counterclockwise, making its plane flush with the upper surface of the receiving plate, allowing the second forging to roll down and contact the baffle. The forgings rolling into the receiving plate are then pushed into the feed inlet of the forging heating furnace by a pusher cylinder.

[0061] In this embodiment, in step (2), qualified forgings are fed into the forging machine and scrap is kicked out by a forging conveying device. The forging conveying device includes a chain conveyor belt B10 arranged horizontally and connected to the output end of the forging heating furnace. A temperature probe B20 is provided on the upper side of the output end of the conveyor belt to detect the temperature of each forging. An inclined discharge chute B30 is provided on the output end side of the conveyor belt, and a scrap kicking mechanism is provided on the discharge chute. An inclined distribution chute B40 is connected to the lower end of the discharge chute. The distribution chute is connected to a first conveying channel B41 and a second conveying channel B42. A distribution baffle B43 is provided in the distribution chute to allow the forgings to enter the first or second conveying channel, so that the forgings can be sent to different forging equipment as needed, or only the first conveying channel can be opened. The temperature probe is electrically connected to the scrap removal mechanism via the controller. When the temperature probe detects that the output temperature of the forging material from the forging heating furnace is not up to standard, the scrap removal mechanism is activated to remove the substandard forging material, thus preventing it from being sent into the forging equipment.

[0062] In this embodiment, the first conveying channel spirals downward, and the output end of the first conveying channel and the second conveying channel is connected to a receiving platform located on one side of the forging machine, so that it can be manually or by a robotic arm clamped into the forging machine.

[0063] In this embodiment, to ensure better operation of the chain conveyor belt, support rollers B11 are provided at lateral intervals on the lower side of the working surface of the chain drive belt. Baffles B12 are fixed on both sides of the conveyor belt to prevent the forging material from falling off the conveyor belt.

[0064] In this embodiment, to better remove substandard forgings, the scrap removal mechanism includes gates B31 on both side plates of the discharge chute. Each gate is connected to a downwardly inclined guide plate B32. The lower end of each guide plate is connected to a vertically arranged scrap outlet pipe B38, and the lower end of the scrap outlet pipe is equipped with a receiving basket B39 to collect substandard forgings. A distribution guide plate B33, rotatably connected to the discharge chute, is installed on each gate. A first driving mechanism is provided on the lower side of the discharge chute to drive the distribution guide plate to swing towards another distribution guide plate, thereby diverting the forgings into the corresponding guide plate. Substandard forgings are then directed into the corresponding guide plate. Limiting plates B34 are also provided on both side plates of the discharge chute to limit the distribution guide plates and prevent them from swinging outwards.

[0065] In this embodiment, the first driving mechanism includes a first driving cylinder B35 whose housing is hinged to the bottom surface of the discharge trough. The lower part of the material distribution guide plate is rotatably connected to the discharge trough via a rotating shaft B36 passing through the discharge trough. A connecting rod B37 is fixed to the lower end of the rotating shaft, and the connecting rod is hinged to the telescopic rod of the first driving cylinder. Thus, the material distribution guide plate swings around the rotating shaft through the telescopic action of the first driving cylinder.

[0066] In this embodiment, the first conveying channel is connected to the lower end of the distribution trough, and the second conveying channel is connected to one side of the distribution trough. The distribution plate is disposed on the inlet port B46 of the second conveying channel. A second driving mechanism is provided on the lower side of the distribution trough to drive the distribution plate to swing, thereby diverting the forging material into the second conveying channel. Thus, the first or second channel can be opened as needed, or the distribution plate can be driven to swing back and forth by the second driving mechanism, achieving switching between the first and second output channels and allowing the forging material to alternately enter different conveying channels.

[0067] In this embodiment, the second driving mechanism includes a second driving cylinder B44 whose housing is hinged to the bottom surface of the material distribution trough. The lower part of the material distribution plate is fixed with a driving shaft that passes through the material distribution trough. The lower end of the driving shaft is fixed with a connecting rod B45, which is hinged to the telescopic rod of the second driving cylinder.

[0068] The forging furnace outputs heated forgings into a chain conveyor belt. Temperature probes monitor the forging temperature; once the set temperature is reached, the forgings sequentially pass through the discharge chute and distribution chute into the first conveying channel. When the forging temperature is below the set point, the temperature probe converts the temperature into a signal and transmits it to the controller. The controller then sends a signal to activate the first drive cylinder, swinging the upper end of one distribution guide plate towards the other, opening the gate on that side to allow substandard forgings to exit. When one side's receiving basket is full, the waste discharge pipe and receiving basket on the other side can be used.

[0069] In this embodiment, in step (3), the hollow frustum-shaped forging after eddy current testing is conveyed to the transition conveyor belt C2 and then fed into the loading conveyor belt C4 of the magnetic detection device by the multi-axis robot C24. A magnetic detection spraying mechanism C5 is provided at the input end of the loading conveyor belt, and a magnetic field transmitting device C6 is provided below the loading conveyor belt. The magnetic field transmitting device is existing technology and will not be described in detail. In use, the workpiece that has passed the eddy current test is manually placed onto the transition conveyor belt and then conveyed to the loading conveyor belt. The magnetic detection spraying mechanism on the loading conveyor belt sprays the workpiece from top to bottom and inside to complete the spraying of the magnetic detection fluid. Then, it is magnetized by the magnetic field transmitting device and conveyed to the inspection personnel for testing.

[0070] In this embodiment, the feeding conveyor belt includes a housing C7. Inside the housing, a plurality of guide rollers C8 are rotatably connected at intervals along the conveying direction. Sprockets C9 are installed at both ends of the guide rollers. The sprockets on the same side of each guide roller are connected by chains C10. A plurality of conveying plates C11 are arranged at intervals between the two chains along the movement direction of the chains. Workpiece limiting structures C12 are symmetrically arranged on the left and right sides of the conveying plates. The workpieces are limited by the workpiece limiting structures to prevent them from falling off the conveying plates.

[0071] In this embodiment, in order to limit the workpiece, the workpiece limiting structure includes a platform-shaped limiting seat C13, and an abutment post C14 is provided on the upper part of the platform-shaped limiting seat. The workpiece is fitted onto the platform-shaped limiting seat to prevent it from falling out. The platform-shaped limiting seat is fixed to the conveyor plate. The two ends of the conveyor plate are locked to the chain by bolts. Each tooth of the chain is provided with a connecting piece C15, and the connecting piece is screwed to the corresponding end of the conveyor plate.

[0072] In this embodiment, the magnetic flux coating mechanism includes a storage tank C16 located beside the housing, which stores magnetic flux C17. Two upward-facing nozzles C18, corresponding to the bottom of the workpiece, are provided on the housing at the input end of the feeding conveyor belt. These upward-facing nozzles are connected to the storage tank via a parallel pipe equipped with a water pump. Two downward-facing spray nozzles C19, corresponding to the top surface of the workpiece, are provided in the middle of the feeding conveyor belt. These spray nozzles are connected to the storage tank via a parallel pipe equipped with a water pump. A tray C20, for receiving falling magnetic flux, is provided at the bottom of the housing. This tray is connected to the storage tank via a pipe equipped with a water pump. To facilitate the reuse of the magnetic flux, an inclined guide plate C21 is provided at the bottom of the tray. An output hole C22 is provided at the inclined lower end of the inclined guide plate, and a filter screen is provided on the output hole. When using the magnetic detection spraying mechanism, the mechanism first clamps the workpiece onto the upward-facing nozzle, which sprays magnetic detection fluid onto the bottom of the workpiece. Then, the workpiece is placed on the platform-type limiting seat and transported to the spray nozzle via the feeding conveyor belt. The spray nozzle sprays magnetic detection fluid onto the entire surface of the workpiece, which is then magnetized by the magnetic field transmitting device for easy manual inspection.

[0073] In this embodiment, to facilitate gripping by a multi-axis robotic arm, the transition conveyor belt includes a support C25, on which a conveyor belt C26 is mounted. Several partitions C27 are spaced apart above the conveyor belt on the support, dividing the conveyor belt into several conveying channels C28. The bottom ends of the partitions on the same side are connected by a connecting plate C29, which is attached to the surface of the conveyor belt. The partitions located at the edges are fixed to the support, and the spacing between the partitions matches the workpiece. The conveying channels are used to convey the workpiece.

[0074] In this embodiment, a manual observation platform C30 is provided at the output end of the feeding conveyor belt. The manual observation platform and the middle part of the feeding conveyor belt are both located in an existing observation room. The observation room contains fluorescent lamps for observation. An output conveyor belt C31 is provided on the side of the manual observation platform. An existing demagnetizer C32 is provided on the output conveyor belt.

[0075] In this embodiment, the workpiece anti-rust spraying device includes a housing D10, and the demagnetizer C32 is located between the feed inlet of the housing and the output conveyor belt C31. A mesh conveyor belt D20 with both ends extending out of the housing is horizontally arranged inside the housing, which facilitates the spraying of the anti-rust liquid and the blowing of air. A rust-preventive spray pipe D30 is longitudinally arranged inside the machine casing near the feed inlet D11, located on the upper and lower sides of the mesh conveyor belt. A blowing assembly is arranged inside the machine casing on the upper and lower sides of the mesh conveyor belt and behind the rust-preventive spray pipes. The blowing assembly includes a first blowing trough D41 longitudinally arranged inside the machine casing and located on the upper side of the mesh conveyor belt, with the air outlet of the first blowing trough facing downwards. A second blowing trough D42 with an air outlet facing upwards is arranged below and behind the first blowing trough. A third blowing trough D43 with an air outlet facing downwards and angled towards the machine casing is also arranged above the discharge outlet D12 of the machine casing. In this way, the rust-preventive liquid on the workpiece is blown off by the three blowing channels, avoiding excessive rust-preventive liquid residue on the workpiece.

[0076] In this embodiment, in order to better spray the rust-preventive liquid, the rust-preventive spray pipe is provided with nozzles spaced longitudinally. The nozzles on the upper rust-preventive spray pipe face downwards, and the nozzles on the lower rust-preventive spray pipe face upwards, so as to spray the upper and lower surfaces of the workpiece comprehensively.

[0077] In this embodiment, to receive the sprayed rust-preventive liquid and the rust-preventive liquid blown off by the air duct, a receiving trough D31 for receiving the rust-preventive liquid is provided inside the machine housing below the mesh conveyor belt. One end of the receiving trough is connected to a collection tank D32, and the end of the receiving trough connected to the collection tank is inclined downwards. A liquid pump D33 is installed on the collection tank, and the output end of the liquid pump is connected to the rust-preventive spray pipe via a bag filter D34. This allows the sprayed rust-preventive liquid to be recovered, filtered again through the bag filter, and then pumped back into the spray pipe, achieving reuse of the rust-preventive liquid. A pressure gauge is installed on the bag filter so that the filter bag inside the bag filter is cleaned when the pressure on the pressure gauge exceeds a certain value.

[0078] In this embodiment, the spray pipe and the second air duct located on the lower side are both positioned between the upper working surface D21 and the lower working surface D22 of the mesh conveyor belt, which facilitates spraying rust-preventive liquid onto the lower surface of the workpiece and blowing off the rust-preventive liquid from the bottom surface of the workpiece. The first air duct, the second air duct, and the third air duct are respectively connected to corresponding blowers via pipes to provide air sources for the first air duct, the second air duct, and the third air duct. The first air duct, the second air duct, and the third air duct are all strip-shaped air chambers and are provided with strip-shaped air outlets.

[0079] In this embodiment, to facilitate the receiving of workpieces after rust prevention treatment, a downward-sloping guide plate D50 is provided on the output end side of the mesh conveyor belt, and a receiving platform D60 is provided at the lower end of the guide plate. To prevent workpieces from slipping off the guide plate, protective plates D51 are provided on both sides of the guide plate. To reduce noise when the workpiece contacts the receiving platform, the platform surface is inclined and covered with noise-reducing mesh plates D61.

[0080] In this embodiment, a circulating cooling device is connected to the outlet of the heat treatment furnace E1. The circulating cooling device includes a heat dissipation channel E2, a conveyor belt E3 that connects to the discharge port of the heat treatment machine, the conveyor belt extending out of the heat dissipation channel, an air cooling mechanism E4 on the heat dissipation channel, a circulating water cooling mechanism E5 on the heat dissipation channel, and a receiving mechanism E6 that connects to the output end of the conveyor belt on the outlet of the heat dissipation channel. In use, the workpiece is rapidly cooled by dual cooling through the air cooling mechanism and the circulating water cooling mechanism.

[0081] In this embodiment, to facilitate rapid ventilation, the air-cooling mechanism includes an air intake device E7 and an exhaust device E8 located at the input and output ends of the heat dissipation channel, respectively. The input end of the heat dissipation channel has several air intake holes E9. The air intake device includes several blowers E10 connected to the air intake holes. The top of the output end of the heat dissipation channel has several exhaust holes E11. A vertical exhaust duct E12 is connected to the exhaust hole. The exhaust device includes several exhaust fans E13 installed on the exhaust duct. The exhaust device is positioned upwards to prevent hot air from blowing directly onto the staff behind, thus improving safety.

[0082] In this embodiment, an inclined guide plate E14, with its lower end tilted towards the conveyor belt output end, is installed on the top inner wall of the heat dissipation channel input end corresponding to the air inlet hole. A horizontal extension plate E15 is provided at the upper end of the inclined guide plate. The horizontal extension plate is fixed to the side of the air inlet hole away from the conveyor belt output end. The guide plate prevents air from moving backward into the heat treatment furnace. At the same time, the airflow caused by the wind further drives the gas at the output end of the heat treatment furnace, preventing air from moving backward into the heat treatment furnace.

[0083] To achieve water circulation and heat dissipation, the circulating water cooling mechanism includes an upper tube group E16 and a lower tube group E17. The upper and lower tube groups are located in the heat dissipation channel and on the upper and lower sides of the conveyor belt, respectively. Each upper and lower tube group consists of several horizontally arranged horizontal tubes E18 arranged from front to back. The two ends of the horizontal tubes of the upper and lower tube groups extend through the heat dissipation channel to form protruding ends. One protruding end is connected to the water source via a parallel pipe with a water source, and the other protruding end is also connected to the water source via a parallel pipe. In use, water flows through the horizontal tubes. The water is continuously drawn from the water source into the horizontal tubes, and then carries away the heat back to the water source, realizing the rapid extraction of heat from the heat dissipation channel. An existing heat exchanger can be installed on the hot water pipes drawn from the horizontal tubes to reduce energy waste.

[0084] In this embodiment, a filter device E19 is connected to the output end of a parallel pipe without a water source. The output end of the filter device is connected to an external water source via a pipeline. The filter device includes a filter cylinder E20, the lower end of which is closed. The output end of the parallel pipe extends into the filter cylinder. An existing filter plate B21 is installed inside the filter cylinder to filter water that carries away heat and prevent clogging of the pipeline. A connection port E22 is provided on the closed surface at the lower end of the filter cylinder, and the connection port is connected to an external water source via a pipeline.

[0085] The above description is only a preferred embodiment of the present invention. For those skilled in the art, designing different forms of bevel gear forging blank production methods according to the teachings of the present invention does not require creative labor. All equivalent changes, modifications, substitutions and variations made in accordance with the scope of the patent application of the present invention without departing from the principles and spirit of the present invention shall be covered by the present invention.

Claims

1. A method for producing a bevel gear forging blank, characterized in that, Includes the following steps: (1) First, the cut forging material is fed into the forging heating furnace through the feeding mechanism for heating; the feeding mechanism includes an inclined support plate, a gantry is horizontally spanned at the lower part of the support plate, and an inclined and elastic buffer plate is fixed on the lower side of the gantry. The lower end of the buffer plate is an arc-shaped part and is used to contact the upper end of the arc-shaped surface of the second forging material; a material blocking mechanism is provided at the lower part of the support plate and in front of the gantry, and a receiving plate with a V-shaped cross section is provided at the lower front side of the support plate. One side of the receiving plate is connected to the forging heating furnace, and a pushing mechanism for pushing the forging material into the forging heating furnace is provided on the other side of the receiving plate. A fixed baffle is provided on one side of the material support plate, and an adjustable baffle is placed on the material support plate. The adjustable baffle is provided with a pair of adjusting grooves, and the adjusting baffle is connected and fastened to the material support plate by fastening bolts passing through the adjusting grooves. The material feeding mechanism includes a slot arranged horizontally at the lower part of the material support plate. A rotating plate with a semi-circular cross-section is arranged horizontally in the slot. The two ends of the rotating plate are rotatably connected to the material support plate. A baffle is fixed horizontally on the plane of the rotating plate. A drive mechanism for driving the rotating plate to rotate forward and backward is provided on the lower side of the material support plate. (2) The temperature of the forging material sent from the forging heating furnace is tested. Forging materials that reach 1200°C are sent into the forging forming machine and forged into a hollow frustum shape; forging materials that cannot reach 1200°C are rejected. (3) The cooled hollow frustum forging is fed into an eddy current machine for eddy current testing, and then into a magnetic detection device for electromagnetic flaw detection to remove defective hollow frustum forgings; the hollow frustum forgings after eddy current testing are transported to a transition conveyor belt and fed into the loading conveyor belt of the magnetic detection device by a robot arm. A magnetic detection spraying mechanism is provided at the input end of the loading conveyor belt, and a magnetic field transmitting device is provided below the loading conveyor belt; the magnetic detection spraying mechanism includes a liquid storage tank located next to the housing, which stores magnetic detection liquid; two upward nozzles corresponding to the bottom of the workpiece are provided on the housing at the input end of the loading conveyor belt, and the upward nozzles are connected to the liquid storage tank via a parallel pipe with a water pump; two downward spray nozzles corresponding to the top surface of the workpiece are provided in the middle of the loading conveyor belt, and the spray nozzles are connected to the liquid storage tank via a parallel pipe with a water pump; a tray for receiving the falling magnetic detection liquid is provided at the bottom of the housing, and the tray is connected to the liquid storage tank via a pipeline with a water pump; (4) The hollow frustum-shaped forgings without defects after electromagnetic flaw detection are demagnetized and sent to the workpiece anti-rust spraying device for anti-rust treatment; the workpiece anti-rust spraying device includes a machine box, a demagnetizer is provided at the feed inlet of the machine box, a mesh chain conveyor belt with both ends passing through the machine box is arranged horizontally inside the machine box, and anti-rust spraying pipes located on the upper and lower sides of the mesh chain conveyor belt are arranged vertically inside the machine box near the feed inlet side, and a blowing assembly is arranged inside the machine box on the upper and lower sides of the mesh chain conveyor belt and on the rear side of the anti-rust spraying pipe; the blowing assembly includes a first blowing trough arranged vertically inside the machine box and on the upper side of the mesh chain conveyor belt, the air outlet of the first blowing trough faces downward, a second blowing trough with the air outlet facing upward is arranged below the rear side of the first blowing trough, and a third blowing trough with the air outlet facing downward is also arranged above the discharge port of the machine box; (5) After rust prevention treatment, the hollow frustum-shaped forgings are sent in batches to the heat treatment furnace for heat treatment. The heat treatment holding temperature is controlled at 935~940℃. The workpiece after heat treatment and cooling is the bevel gear forging. The outlet of the heat treatment furnace is connected to a circulating cooling device. The circulating cooling device includes a heat dissipation channel. An inclined guide plate is installed on the inner wall of the top of the input end of the heat dissipation channel corresponding to the air inlet. The lower end of the inclined guide plate is inclined towards the output end of the conveyor belt. A horizontal extension plate is provided on the upper end of the inclined guide plate. The horizontal extension plate is fixed on the side of the air inlet away from the output end of the conveyor belt.

2. The method for producing a bevel gear forging blank according to claim 1, characterized in that, In step (2), qualified forgings are fed into the forging machine and scrap is kicked out by the forging material conveying device. The forging material conveying device includes a chain conveyor belt arranged horizontally and connected to the output end of the forging heating furnace. A temperature probe is provided on the upper side of the output end of the chain conveyor belt. An inclined downward discharge chute is provided on the output end side of the chain conveyor belt. A scrap kicking mechanism is provided on the discharge chute. An inclined downward distribution chute is connected to the lower end of the discharge chute. The distribution chute is connected to a first conveying channel and a second conveying channel that are respectively sent to the forging machine. A distribution plate is provided in the distribution chute to allow the forgings to enter the first conveying channel or the second conveying channel.

3. The method for producing a bevel gear forging blank according to claim 2, characterized in that, The waste removal mechanism includes gates on both side plates of the discharge chute, with downwardly inclined guide plates connected to the gates. The lower end of the guide plates is connected to a vertically arranged waste discharge pipe, and a receiving basket is provided at the lower end of the waste discharge pipe. A material distribution guide plate with its lower part rotatably connected to the discharge chute is installed on the gates, and a first driving mechanism is provided on the lower side of the discharge chute to drive the material distribution guide plate to swing towards another material distribution guide plate to divert the forging material into the guide plate.

4. The method for producing a bevel gear forging blank according to claim 2, characterized in that, The first conveying channel spirals downwards, and the output end of the first and second conveying channels is connected to a receiving platform located on one side of the forging machine.

5. A method for producing a bevel gear forging blank according to claim 1, 3, or 4, characterized in that, In step (3), the feeding conveyor belt includes a housing, and a number of guide rollers are rotatably connected at intervals along the conveying direction inside the housing. Sprockets are installed at both ends of the guide rollers. The sprockets on the same side of each guide roller are connected by chains. A number of conveying plates are spaced apart between the two chains along the movement direction of the chains. Workpiece limiting structures are symmetrically arranged on the left and right sides of the conveying plates.

6. A method for producing a bevel gear forging blank according to claim 1, 2, 3 or 4, characterized in that, The heat dissipation channel is equipped with a conveyor belt that connects to the discharge port of the heat treatment furnace. The conveyor belt extends out of the heat dissipation channel. An air-cooling mechanism is installed on the heat dissipation channel. A circulating water-cooling mechanism is installed inside the heat dissipation channel. A receiving mechanism that connects to the output end of the conveyor belt is installed at the outlet of the heat dissipation channel.

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