An engine end cover production rhythm optimization device and optimization method

Abstract

The application discloses an engine end cover production rhythm optimization device, comprising: an outer end face milling station for outer end face machining of a workpiece; an inner end face milling station for inner end face machining of the workpiece; a circulation station for high-precision circulation machining of the outer end face and the inner end face of the workpiece; a side end face milling station for side end face machining of the workpiece; a robot for transferring the workpiece; a flash tester for detecting whether the workpiece on the circulation station is qualified; and an industrial control unit for controlling the outer end face milling station, the inner end face milling station, the circulation station, the side end face milling station, the robot and the flash tester. The engine end cover production rhythm optimization method reduces machining time, improves machining efficiency, reduces machining cost and improves economic benefits. The flash tester is used for online detection and data feedback, and after meeting the machining requirements, side end face milling is directly performed, so that the original milling process is repeated for several times and the milling steps are simplified.

Description

Technical Field

[0001] This invention relates to an engine end cover production system, and more specifically, to an engine end cover production cycle optimization device and method. Background Technology

[0002] The cylinder head is a core component of the engine, and end milling plays an important role in the machining of this component. The top and bottom surfaces, as well as the front and rear surfaces of the cylinder head, have high requirements for roughness and flatness. Failure to meet these requirements will have a significant impact on the performance and quality of the engine.

[0003] Engine end cover parts are primarily made of aluminum alloy, generally characterized by thin walls and susceptibility to deformation under stress. The structure of engine end cover parts is complex, and the precision of each component affects characteristics such as engine airtightness; therefore, higher precision is required in their machining. Taking automotive engines as an example, the shape and position of the end cover are precisely designed for each engine model, imposing high precision requirements on the roundness, coaxiality, position, and perpendicularity of each component. However, during actual machining, the workpiece undergoes elastic deformation after clamping. Structures such as the outer diameter lugs of the workpiece are often machined using intermittent cutting methods. Changes in the tool entry point can cause cutting marks, and combined with elastic deformation, the flatness, roundness, and coaxiality of the inner hole may exceed the design error range. Therefore, it is necessary to optimize the machining scheme and specific machining process. However, many patents describe end cover milling as inefficient and with limited application scope. Summary of the Invention

[0004] Therefore, it is necessary to provide a method for optimizing the production cycle of engine end caps to address the aforementioned technical problems.

[0005] To solve the above-mentioned technical problems, the present invention adopts the following technical solution:

[0006] An engine end cover production cycle optimization device, characterized in that the engine end cover production cycle optimization device comprises:

[0007] The outer end milling station is used for machining the outer end face of the workpiece.

[0008] The inner end face milling station is used for machining the inner end face of the workpiece.

[0009] Circular workstations are used for high-precision cyclic machining of the outer and inner end faces of workpieces.

[0010] Side end milling station, used for machining the side end face of the workpiece;

[0011] Robots are used for transferring workpieces;

[0012] A flash tester is used to detect whether workpieces in a cyclic workstation are qualified.

[0013] The industrial control unit is used to control the outer end face milling station, the inner end face milling station, the cyclic station, the side end face milling station, the robot, and the flash measuring instrument.

[0014] As a preferred embodiment of the present invention, the engine end cover production cycle optimization method includes:

[0015] Step S1: Determine whether the outer end milling station is fully loaded. If it is not fully loaded, transfer the workpiece to the outer end milling station and process the outer end face of the workpiece. If it is fully loaded, stop the transfer of the workpiece.

[0016] Step S2: Determine whether the inner end face milling station is fully loaded. If it is not fully loaded, transfer the workpiece from the outer end face milling station to the inner end face milling station and process the inner end face of the workpiece. If it is fully loaded, stop the transfer of the workpiece.

[0017] Step S3: After the inner end face milling station is completed, the workpiece is inspected online in real time using a flash meter. If the inspection meets the processing requirements, the workpiece on the inner end face milling station is directly transferred to the side end face milling station to process the side end face of the workpiece. If the inspection does not meet the processing requirements, the workpiece is transferred to the cyclic station for cyclic high-precision milling until the processing accuracy of the outer end face and inner end face of the workpiece meets the processing requirements. Then, the workpiece is transferred to the side end face milling station to process the side end face of the workpiece.

[0018] In a preferred embodiment of the present invention, in step S3, before transferring the workpiece to the side end milling station, it is necessary to determine whether the side end milling station is fully loaded.

[0019] Before transferring the workpiece to the circulating station, it is necessary to determine whether the circulating station is fully loaded.

[0020] In a preferred embodiment of the present invention, binocular vision sensors are provided at the outer end milling station, the inner end milling station, the cyclic station, and the side end milling station to collect information at the station and thus determine whether the station is fully loaded.

[0021] In a preferred embodiment of the present invention, in steps S1 and S2, a small machining allowance is retained or no machining allowance is retained.

[0022] In a preferred embodiment of the present invention, the flash detector is installed on a cyclic workstation.

[0023] Compared with the prior art, the present invention has the following beneficial effects:

[0024] This invention provides a method for optimizing the production cycle time of engine end covers. This method reduces processing time, improves processing efficiency, lowers processing costs, and increases economic benefits. The outer end face milling station D1 and the inner end face milling station D2 directly perform high-precision machining to ensure the machining accuracy meets assembly requirements. An online inspection instrument is used for online detection and data feedback. Once the processing requirements are met, the side end face milling at the side end face milling station D4 is directly performed. This reduces the number of repetitions in the original milling process and simplifies the milling steps. Attached Figure Description

[0025] To more clearly illustrate the solutions in this invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the drawings described below are some embodiments of this invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0026] Figure 1 This is a schematic diagram of the logical structure of the engine end cover production cycle optimization method of the present invention;

[0027] Figure 2 for Figure 1 A schematic diagram of the module connection of the engine end cover production cycle optimization device. Detailed Implementation

[0028] The preferred embodiments of the present invention will now be described in detail with reference to the accompanying drawings, so that the advantages and features of the present invention can be more easily understood by those skilled in the art, thereby providing a clearer and more explicit definition of the scope of protection of the present invention.

[0029] like Figure 1 and Figure 2 As shown, the engine end cover production cycle optimization device includes:

[0030] External end face milling station D1 is used for machining the external end face of the workpiece;

[0031] Internal end face milling station D2 is used for machining the internal end face of the workpiece;

[0032] Cyclic station D3 is used for high-precision cyclic machining of the outer and inner end faces of the workpiece;

[0033] Side end milling station D4 is used for machining the side end face of the workpiece;

[0034] Robot D5 is used for workpiece transfer;

[0035] The flash tester D6 is used to detect whether the workpieces on the cycle station D3 are qualified.

[0036] The industrial control unit D7 is used to control the outer end face milling station D1, the inner end face milling station D2, the cycle station D3, the side end face milling station D4, the robot D5, and the flash measuring instrument D6.

[0037] The method for optimizing the production cycle time of the engine end cover includes:

[0038] Step S1: Determine whether the outer end milling station D1 is fully loaded. If it is not fully loaded, transfer the workpiece to the outer end milling station D1 and process the outer end face of the workpiece. If it is fully loaded, stop the transfer of the workpiece.

[0039] Step S2: Determine whether the inner end face milling station D2 is fully loaded. If it is not fully loaded, transfer the workpiece from the outer end face milling station D1 to the inner end face milling station D2 and process the inner end face of the workpiece. If it is fully loaded, stop the transfer of the workpiece.

[0040] Step S3: After the inner end face milling station D2 is completed, the workpiece is inspected online in real time using the flash meter D6. If the inspection meets the processing requirements, the workpiece on the inner end face milling station D2 is directly transferred to the side end face milling station D4 to process the side end face of the workpiece. If the inspection does not meet the processing requirements, the workpiece is transferred to the cycle station D3 for cyclic high-precision milling until the processing accuracy of the outer end face and inner end face of the workpiece meets the processing requirements. Then, the workpiece is transferred to the side end face milling station D4 to process the side end face of the workpiece.

[0041] It should be noted that in step S3, before transferring the workpiece to the side end milling station D4, it is necessary to determine whether the side end milling station D4 is fully loaded. In steps S1 and S2, in order to improve processing efficiency and reduce production costs, a small machining allowance may be retained or no machining allowance may be retained.

[0042] In addition, before transferring the workpiece to the cycle station D3, it is necessary to determine whether the cycle station D3 is fully loaded.

[0043] Binocular vision sensors are installed at the outer end milling station D1, inner end milling station D2, circulating station D3, and side end milling station D4 to collect information at each station and determine whether the station is fully loaded. The determination of station full load is achieved through a combination of sensor data acquisition and automated production line operation. When the station is not fully loaded, the sensor sends a push command signal, and the conveyor belt moves forward to transport the workpiece. When the station is fully loaded, the sensor sends a stop push command signal, and the conveyor belt stops running.

[0044] The transport and clamping are handled by a D5 transport robot. The D5 robot places the workpiece on a conveyor belt for transport. After the workpiece is transported to the processing station, the sensor sends a stop-progress command signal, and the robotic arm lifts the workpiece and places it in the milling fixture.

[0045] The flash detector D6 is installed on the cyclic station D3. The working principle of the flash detector D6 will be further explained below.

[0046] The D6 flash meter is used for online real-time inspection of processed samples, with the inspection data fed back through the output terminal. The flash meter is mounted on the worktable with its lens facing the stage. The workpiece is placed on the stage, and with a single press of a button, the lens quickly captures an image of the entire workpiece, automatically measuring the selected elements and all dimensions in one go. The CAD dimensions are directly imported for comparison with the physical sample. Multiple products (approximately 50) can be placed simultaneously for rapid inspection (approximately 1.5 seconds). The worktable does not need to move during the measurement process, making it suitable for online batch inspection. It dynamically identifies the position and origin, eliminating the need for alignment. The flash meter sends the inspection signal directly to the industrial control unit D7.

[0047] This engine end cover production cycle optimization method reduces processing time, improves processing efficiency, lowers processing costs, and enhances economic benefits. High-precision machining is performed directly at the outer end face milling station D1 and the inner end face milling station D2, ensuring the machining accuracy meets assembly requirements. An online inspection instrument is used for data feedback; once the processing requirements are met, side end face milling at station D4 is performed directly. This reduces the number of repetitions in the original milling process, simplifying the milling steps.

[0048] Not limited to this, any variations or substitutions conceived without inventive effort should be included within the scope of protection of this invention. Therefore, the scope of protection of this invention should be determined by the scope defined in the claims.

Claims

1. A method for optimizing the production cycle time of engine end covers, applied to an engine end cover production cycle time optimization device, characterized in that, The engine end cover production cycle optimization method includes: Step S1: Determine whether the outer end milling station (D1) is fully loaded. If it is not fully loaded, transfer the workpiece to the outer end milling station (D1) and process the outer end face of the workpiece. If it is fully loaded, stop the transfer of the workpiece. Step S2: Determine whether the inner end milling station (D2) is fully loaded. If it is not fully loaded, transfer the workpiece on the outer end milling station (D1) to the inner end milling station (D2) and process the inner end face of the workpiece. If it is fully loaded, stop the transfer of the workpiece. Step S3: After the inner end face milling station (D2) finishes machining, use a flash meter (D6) to perform online real-time inspection of the workpiece. If the inspection meets the machining requirements, the workpiece on the inner end face milling station (D2) is directly transferred to the side end face milling station (D4) to machine the side end face of the workpiece. If the inspection does not meet the machining requirements, the workpiece is transferred to the cyclic station (D3) for cyclic high-precision milling until the machining accuracy of the outer end face and inner end face of the workpiece meets the machining requirements. Then, the workpiece is transferred to the side end face milling station (D4) to machine the side end face of the workpiece. in, In step S3, before transferring the workpiece to the side end milling station (D4), it is necessary to determine whether the side end milling station (D4) is fully loaded. Before transferring the workpiece to the cycle station (D3), it is necessary to determine whether the cycle station (D3) is fully loaded. Binocular vision sensors are installed at the outer end milling station (D1), inner end milling station (D2), circulating station (D3) and side end milling station (D4) to collect information at the station and determine whether the station is fully loaded. In steps S1 and S2, a small machining allowance may be retained or no machining allowance may be retained. The aforementioned flash detector (D6) is installed on the cyclic workstation (D3); The engine end cover production cycle optimization device includes: The outer end milling station (D1) is used for machining the outer end face of the workpiece. The inner end face milling station (D2) is used for machining the inner end face of the workpiece; The cyclic station (D3) is used for high-precision cyclic machining of the outer and inner end faces of the workpiece; Side end milling station (D4) is used for machining the side end face of the workpiece; Robot (D5), used for workpiece transfer; The flash tester (D6) is used to detect whether the workpieces on the cycle station (D3) are qualified; The industrial control unit (D7) is used to control the outer end milling station (D1), inner end milling station (D2), cycle station (D3), side end milling station (D4), robot (D5) and flash meter (D6).

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