Full-automatic winding of special-shaped complex component metal rubber blank intelligent device and working method thereof
By using a fully automated intelligent device for winding complex metal rubber blanks with irregular shapes, and employing fixed-pitch stretching and dynamic control technology, the problems of consistency and automated preparation in the production of metal rubber blanks have been solved, achieving efficient and uniform production of metal rubber blanks.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- FUZHOU UNIV
- Filing Date
- 2024-01-23
- Publication Date
- 2026-07-24
AI Technical Summary
Most existing metal rubber blank manufacturing equipment is semi-automatic and has unsatisfactory precision control, resulting in low consistency in the production of metal rubber blanks and making it difficult to achieve automated preparation of irregular and complex structures.
A fully automated intelligent device for winding complex metal-rubber blanks was designed. It employs components such as a fixed-pitch stretching device, a rotary motor, a shearing disc device, and a torque sensor to achieve precise control and automated winding of the metal spiral coil. The pitch stretching and winding angle are dynamically controlled by a PLC and computer.
It has achieved fully automated production of metal-rubber blanks, improved the consistency and uniformity of preparation, met the design requirements of irregular and complex structures, and improved productivity.
Smart Images
Figure CN117943484B_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of porous metal-rubber material processing technology, specifically to a fully automated intelligent device for winding complex irregular-shaped metal-rubber blanks and its working method. Background Technology
[0002] Metal rubber is a complex material manufactured by spiraling straight metal wires into a blank and then cold-stamping it. It is a pure metal damping material with a complex spiral network structure. The spatial micro-void physical structure formed by the interlocking wires inside the metal rubber gives it superior vibration damping properties compared to traditional polymer rubber materials. It can also meet the requirements of special environments such as high temperature resistance, low temperature resistance, high pressure resistance and strong vibration resistance.
[0003] In the preparation of metal rubber blanks, the control of the pitch stretching distance of the metal spiral coil and the winding angle of each reciprocating motion has a significant impact on the consistency of the metal rubber. Furthermore, due to the complex and cumbersome manufacturing process of metal rubber, most existing metal rubber blank manufacturing equipment is semi-automatic. Some equipment uses machine vision for pitch stretching control, but the precision control is not ideal, often resulting in poor equipment stability and low production consistency of the metal rubber blanks. Therefore, a fully automatic machine is needed. This machine can not only achieve precise control of the pitch stretching and winding angle of the metal spiral coil in each reciprocating motion, but also automate the preparation of blanks with complex irregular structures with good consistency. Summary of the Invention
[0004] The purpose of this invention is to design a fully automated intelligent device for winding complex metal rubber blanks. This device achieves precise control of the winding angle and pitch stretching in each process of reciprocating motion during the preparation of the metal rubber blank. While ensuring the consistency of the metal rubber blank, it enables the full automation of the preparation of the metal rubber blank and solves the problem of poor consistency of the metal rubber blank.
[0005] The technical solution of the present invention is as follows: a fully automatic intelligent device for winding complex metal rubber blanks of irregular shapes, characterized in that it includes a worktable and a fixed pitch stretching device disposed on the rear side of the worktable. The worktable is provided with a rotary motor for controlling the rotation of the mandrel and a shearing disc device for clamping and cutting the metal spiral coil. The fixed pitch stretching device includes a pulley stretching device and a gantry linear module guide rail for driving the pulley stretching device to move horizontally and vertically. The gantry linear module guide rail is composed of three linear module guide rails. Two linear guide rails are placed on one side of the worktable and are perpendicular to the plane of the worktable. The horizontal linear guide rail is used to place the pulley stretching device for controlling the fixed pitch stretching of the metal spiral coil.
[0006] The workbench is equipped with a stand between the fixed pitch stretching device and the mandrel. The stand is equipped with a hopper for placing the metal spiral coil and a spiral coil auxiliary feed pulley for assisting in controlling the feeding of the metal spiral coil.
[0007] Furthermore, the aforementioned hopper is equipped with a tension sensor that monitors the tension of the spiral winding. The gantry linear module guide rail consists of three linear module guide rails, two of which are placed on the rear side of the worktable and perpendicular to the worktable plane. A pulley tensioning device is placed on one of the horizontal linear guide rails. The two ends of the horizontal linear guide rail are connected to the sliders of the two vertical linear guide rails to realize the longitudinal movement of the horizontal linear guide rail. The pulley tensioning device moves laterally on the horizontal linear guide rail.
[0008] Furthermore, the aforementioned pulley tensioning device includes a rotating bracket, a tension pulley, an auxiliary tension pulley, a torque sensor for monitoring pulley torque, a rectangular housing, a pulley drive motor, a rotating support base, and a sliding base. The tension pulley and the auxiliary tension pulley are horizontally aligned and installed between two parallel rectangular housings. The U-shaped rotating bracket is fixed to the two rectangular housings by bolts. A rotating servo motor installed on the rotating support base is connected to the bottom of the rotating bracket. The rotating bracket is driven to rotate by the rotating servo motor. Torque sensors are installed on the tension pulley and the auxiliary tension pulley.
[0009] Furthermore, a tension sensor is installed on the rear side of the aforementioned hopper, and a torque sensor for monitoring the torque of the spiral feed pulley is also installed on the spiral feed pulley.
[0010] Furthermore, the aforementioned shear-clamp disc device comprises a pulley drive motor, a rotating base, a rotating disc, a sprue clamp, a pneumatic shear, a synchronous belt, a small synchronous pulley, and a large synchronous pulley. The rotating disc has a shaft segment, the end of which is connected to the large synchronous pulley. A hole is drilled at the bottom of the rotating base, through which the output shaft of the pulley drive motor at the bottom of the rotating base is connected to the small synchronous pulley for transmission. The two pulleys are driven by the synchronous belt. The sprue clamp and the pneumatic shear are mounted on the same radial line of the rotating disc, and the distance between the sprue clamp and the center of the rotating disc is greater than the distance between the pneumatic shear and the center of the rotating disc. The initial position of the sprue clamp and the pneumatic shear is set when the radial line of the sprue clamp and the pneumatic shear is parallel to the worktable and close to the fixed-pitch stretching device. Both the sprue clamp and the pneumatic shear are pneumatically controlled.
[0011] Furthermore, a platform is placed below the aforementioned rotary motor so that the axis of the spindle coincides with the axis of the rotating disk when the rotary motor is running.
[0012] Furthermore, the aforementioned tension sensor places its detection end inside the hopper through a hole on the rear side of the hopper, while the main body of the tension sensor is installed on the rear side of the hopper.
[0013] Furthermore, an electrical control cabinet is located next to the aforementioned workbench.
[0014] Furthermore, the aforementioned spiral auxiliary feed pulley is also connected to a second pulley drive motor that drives its rotation.
[0015] The present invention relates to a fully automated intelligent device for winding complex, irregularly shaped metal-rubber blanks, and its operating method.
[0016] The first step is to initialize the components in the device to their initial positions using the initialization procedure.
[0017] The initialization program sets the sprue clamp and pneumatic shear on the rotating disk to their initial positions via a pulley-driven motor.
[0018] The second step is to pre-wrap the metal spiral coil around the tension pulley, the auxiliary tension pulley, and the spiral coil auxiliary feed pulley.
[0019] Place the metal spiral coil inside the hopper, then connect and fix one end of the metal-rubber spiral coil to the tension sensor, pull out the other end and wrap it around the upper groove of the spiral coil auxiliary feed wheel and the lower groove of the auxiliary stretching pulley, and finally wrap it out from the upper groove of the stretching pulley, and finally clamp it with the sprue clamp.
[0020] The third step is to stretch the metal spiral coil to a fixed pitch using a preset program.
[0021] At this time, the pulley drive motor is controlled by the PLC in the electrical control cabinet to drive the tension pulley to rotate. When the tension pulley on the pulley tensioning device rotates, it drives the metal spiral coil to stretch or unwind. At the same time, the torque sensor on the pulley tensioning device monitors the torque of the tension pulley in real time and transmits the data to the computer in the electrical control cabinet. The computer compares the torque value with the torque value required to stretch the 1.8 mm pitch, and transmits the comparison result to the PLC. The PLC then controls the forward and reverse rotation of the pulley drive motor. When the motor rotates forward, the tension on the metal spiral coil between the sprue clamp and the tension pulley decreases, and vice versa, realizing the stretching or unwinding of the metal spiral coil, thereby controlling the pitch of the metal spiral coil to be controlled at 1.8 mm. The pulley drive motor drives the rotating disk to rotate several times, thereby driving the sprue clamp to rotate around the mandrel, initially winding the stretched metal spiral coil onto the mandrel. Then the motor rotates... The machine drives the mandrel to rotate, enabling the metal spiral to continuously wind around the mandrel. A torque sensor on the stretching pulley continuously monitors data during the winding process. Simultaneously, a torque sensor is also installed on the spiral auxiliary feed pulley. By monitoring the torque value on the spiral auxiliary feed pulley, the stress and tension of the metal spiral from the auxiliary stretching pulley to the spiral auxiliary feed pulley are monitored. The torque value on the spiral auxiliary feed pulley is transmitted to the computer, which compares it with the pulley torque value corresponding to the spiral within the elastic deformation range. This controls the rotation of the second pulley drive motor on the auxiliary feed pulley, controlling the stretching and contraction of this part of the metal spiral, preventing the metal spiral from being stretched and formed, which would affect the subsequent fixed-pitch stretching process. It also ensures that the metal spiral does not slip off the spiral auxiliary stretching pulley, ensuring the consistency of the metal and rubber.
[0022] The fourth step involves using a preset program to achieve dynamic coordination of the winding angle control during each process of the metal spiral winding with fixed pitch stretching and reciprocating motion.
[0023] When the rotary motor rotates, the horizontal linear module on the gantry linear guide also slides. By adjusting the sliding speed of the sliding base on the horizontal linear module relative to the winding point on the mandrel, the winding angle of the metal spiral coil in each reciprocating motion can be changed. The winding angle of each reciprocating motion is selected by the computer, and the PLC controls the displacement speed of the sliding base to keep the winding angle of each reciprocating motion within 50 degrees. The direction away from the shearing disc device is taken as the positive direction. When the forward limit is reached (set by the program), the rotary servo motor (not shown in the figure) inside the sliding base operates, driving the rotary support to rotate and thus changing the winding direction of the metal spiral coil. When the return limit is reached (set by the program), its steering principle is the same as the forward stroke.
[0024] Through program control, the PLC controls the rotation of the pulley drive motor and the movement of the sliding base on the gantry linear module guide rail based on the comparison results returned by the computer, so that the monitored value on the torque sensor remains consistent with the required value.
[0025] Fifth step: If you want to interrupt the winding process, you can use a preset program to interrupt the winding process;
[0026] The program is set so that, with the metal spiral coil partially wound around the mandrel, the pulley drive motor drives the sprue clamp back to its initial position. The slider on the vertical guide rail of the gantry linear module, which is connected to the horizontal linear module guide rail, is axially displaced. The sliding base on the horizontal linear module is laterally displaced, so that the section of the metal spiral coil from the mandrel to the tension pulley on the pulley tensioning device is exactly in the opening between the sprue clamp and the pneumatic shear. Then the sprue clamp clamps the metal spiral coil, and the pneumatic shear cuts the metal spiral coil. At this point, the winding process is interrupted, and the mandrel can be directly removed. To start the next winding, the mandrel can be installed, the program can be run, and steps three and four can be repeated to start winding directly.
[0027] Step 6: The winding process is complete; end the winding.
[0028] The program is set so that during the winding process, the pulley drive motor rotates to drive the sprue clamp back to its initial position. Due to continuous winding, most of the metal spiral coil is wound on the mandrel, and the length of the spiral coil in the hopper gradually decreases. Since the tension sensor detection end is connected to the end of the metal spiral coil, when the tension sensor is subjected to a tension greater than the program-set threshold, the rotary motor and the pulley drive motor stop running. The slider on the vertical guide rail of the gantry linear module, which is connected to the horizontal linear module guide rail, is axially displaced, and the sliding base on the horizontal linear module is laterally displaced. This ensures that the section of the metal spiral coil from the mandrel to the tension pulley on the pulley tensioning device is exactly in the opening between the sprue clamp and the pneumatic shear. Then, the sprue clamp is tightened, the pneumatic shear is cut, the mandrel is removed, and finally, the metal rubber blank is prepared on the mandrel.
[0029] Compared with current equipment for producing metal-rubber blanks, the present invention has the following advantages:
[0030] Compared to existing technologies, this equipment optimizes and improves its mechanical structure, and through high electromechanical integration, it achieves precise control of the winding angle in each process of constant pitch stretching and reciprocating motion during the preparation of metal rubber blanks, thereby further improving the consistency and uniformity of the metal rubber.
[0031] Because this equipment dynamically controls the pitch stretching by transmitting data from a torque sensor to a computer in real time, its advantage is that it can more accurately control the fixed pitch stretching through real-time data monitoring.
[0032] Compared to current metal rubber blank production equipment, this equipment achieves fully automated metal rubber blank production while ensuring the consistency of metal rubber. It can also perform multiple preparations when the metal spiral roll length is sufficient, thereby improving the productivity of metal rubber blanks. At the same time, it can also meet the design and preparation of irregular and complex structures.
[0033] Compared to existing metal-rubber blank production equipment, this equipment has clearly defined functions for each module and is easy to assemble and disassemble. Attached Figure Description
[0034] Figure 1 This is a schematic diagram of the isometric structure of the present invention;
[0035] Figure 2 This is a top view of the structure of the present invention;
[0036] Figure 3 This is a side view of the structure of the present invention;
[0037] Figure 4 This is a rear axonometric view of the present invention;
[0038] Figure 5 This is a schematic diagram of the fixed pitch tensioning device of the present invention;
[0039] Figure 6 This is a schematic diagram of the pulley tensioning device of the present invention;
[0040] Figure 7 This is a front view of the shearing disc device structure of the present invention;
[0041] Figure 8 This is a rear view of the shearing disc device structure of the present invention;
[0042] Figure 9 This is a flowchart illustrating the overall workflow of the present invention;
[0043] In the diagram: 1-Upright frame, 2-Fixed pitch tensioning device, 3-Rotary motor, 4-Electrical control cabinet, 5-Upright platform, 6-Workbench, 7-Shear clamp disc device, 8-Mandrel, 9-Pulley tensioning device, 10-Gantry linear module guide rail, 11-Auxiliary tensioning pulley, 12-Tension pulley, 13-Rotating bracket, 14-Rotating support base, 15-Sliding base, 16-Pulley drive motor, 17-Rectangular housing, 18-Torque sensor, 19-Sprue clamp, 20-Rotating disc, 21-Pulley drive motor, 22-Rotating base, 23-Pneumatic shear, 24-Synchronous belt, 25-Large pulley, 26-Small pulley, 27-Hopper, 28-Spiral coil auxiliary feed pulley, 29-Tension sensor. Detailed Implementation
[0044] The fully automatic intelligent device for winding complex metal rubber blanks of irregular shapes of the present invention includes a worktable 6 and a fixed pitch stretching device 2 located on the rear side of the worktable 6. The worktable 6 is provided with a rotary motor 3 for controlling the rotation of the mandrel 8 and a shearing disc device 7 for clamping and cutting the metal spiral coil.
[0045] The shearing disc device 7 consists of a pulley drive motor 21, a rotating base 22, a rotating disc 20, a sprue clamp 19, a pneumatic shear 23, a synchronous belt 24, a small synchronous pulley 26, and a large synchronous pulley 25. The rotating disc has a shaft segment, the end of which is connected to the large synchronous pulley 25. A hole is drilled at the bottom of the rotating base 22, through which the output shaft of the pulley drive motor 21 at the bottom of the rotating base is connected to the small synchronous pulley 26 for transmission. The two pulleys are driven by the synchronous belt. The sprue clamp 19 and the pneumatic shear 23 are installed on the same radial line of the rotating disc 20, and the distance between the sprue clamp 19 and the center of the rotating disc 20 is greater than the distance between the pneumatic shear 23 and the center of the rotating disc 20. The initial position of the sprue clamp 19 and the pneumatic shear 23 is set when their installation radial line is parallel to the worktable and close to the fixed-pitch stretching device 2. Both the sprue clamp and the pneumatic shear are pneumatically controlled.
[0046] The fixed pitch stretching device 2 includes a pulley stretching device 9 and a gantry linear module guide rail 10 for driving the pulley stretching device 9 to move horizontally and vertically. The gantry linear module guide rail 10 is composed of three linear module guide rails. Two linear guide rails are placed on one side of the worktable and are perpendicular to the plane of the worktable 6. The horizontal linear guide rail holds the pulley stretching device 9 for controlling the fixed pitch stretching of the metal spiral coil.
[0047] The pulley tensioning device 9 includes a rotating bracket 13, a tension pulley 12, an auxiliary tension pulley 11, a torque sensor 18 for monitoring pulley torque, a rectangular housing 17, a pulley drive motor 16, a rotating support 14, and a sliding base 15. The tension pulley 12 and the auxiliary tension pulley 11 are horizontally aligned and installed between two parallel rectangular housings 17. The U-shaped rotating bracket 13 is fixed to the two rectangular housings 17 by bolts. A rotating servo motor installed on the rotating support 14 is connected to the bottom of the rotating bracket 13. The rotating bracket 13 is driven to rotate by the rotating servo motor. The torque sensor 18 is installed on the tension pulley 12 and the auxiliary tension pulley 11.
[0048] The workbench 6 is equipped with a stand 1 located between the fixed pitch stretching device 2 and the mandrel 8. The stand 1 is equipped with a hopper 27 for placing the metal spiral coil and a spiral coil auxiliary feed pulley 28 for assisting in controlling the feeding of the metal spiral coil.
[0049] The hopper 27 is equipped with a tension sensor 29 for monitoring the tension of the spiral winding. The gantry linear module guide rail consists of three linear module guide rails, two of which are placed on the rear side of the worktable and perpendicular to the worktable plane. A pulley tensioning device 9 is placed on one of the horizontal linear guide rails. The two ends of the horizontal linear guide rail are connected to the sliders of the two vertical linear guide rails to realize the longitudinal movement of the horizontal linear guide rail. The pulley tensioning device 9 moves laterally on the horizontal linear guide rail.
[0050] A tension sensor 29 is installed on the rear side of the hopper 27, and a torque sensor for monitoring the torque of the spiral feed pulley 28 is also installed on the spiral feed pulley 28.
[0051] A platform 5 is placed below the rotary motor 3 so that the axis of the spindle 8 coincides with the axis of the rotating disk 20 when the rotary motor 3 is running.
[0052] The tension sensor 29 has its detection end placed inside the hopper 27 through a hole on the rear side of the hopper 27, while the main body of the tension sensor 29 is installed on the rear side of the hopper.
[0053] An electrical control cabinet 4 is provided on the side of the workbench 6; a second pulley drive motor is also connected to the spiral auxiliary feed pulley 28 to drive its rotation.
[0054] The following is a detailed description of the specific implementation method for preparing a metal-rubber blank by stretching a metal spiral coil with a pitch of 1.8 mm and reciprocating at 60°, with the winding angle of each process. The invention will be further explained in conjunction with the accompanying drawings.
[0055] The first step is to initialize the components in the device to their initial positions through an initialization procedure.
[0056] The initialization program sets the sprue clamp 19 on the rotating disk 20 and the pneumatic shear 23 to their initial positions via the pulley drive motor 21.
[0057] The second step is to pre-load the metal spiral coil around the tension pulley 12, the auxiliary tension pulley 11, and the spiral coil auxiliary feed pulley 28.
[0058] Place the metal spiral coil in the hopper 27, then connect and fix one end of the metal rubber spiral coil to the tension sensor 29, pull out the other end and wrap it around the upper groove of the spiral coil auxiliary feed wheel 28, the lower groove of the auxiliary tension pulley 11, and finally out from the upper groove of the tension pulley 12. Finally, clamp it with the sprue clamp 19.
[0059] The third step involves stretching the metal spiral coil to a fixed pitch using a pre-set program.
[0060] At this time, the pulley drive motor 16 is controlled by the PLC in the electrical control cabinet 4 to drive the tension pulley 12 to rotate. When the tension pulley 12 on the pulley tensioning device 9 rotates, it drives the metal spiral coil to stretch or unwind. At the same time, the torque sensor 18 on the pulley tensioning device 9 monitors the torque of the tension pulley 12 in real time and transmits the data to the computer in the electrical control cabinet 4. The computer compares the torque value with the torque value required to stretch the screw pitch of 1.8 mm, and transmits the comparison result to the PLC. The PLC then controls the forward and reverse rotation of the pulley drive motor 16. When the motor rotates forward, the tension on the metal spiral coil between the sprue clamp 19 and the tension pulley 12 decreases, and vice versa, realizing the stretching or unwinding of the metal spiral coil, thereby controlling the screw pitch of the metal spiral coil to be controlled at 1.8 mm. The pulley drive motor 21 drives the rotating disk 20 to rotate several times, thereby driving the sprue clamp 19 to rotate around the mandrel 8, initially winding the stretched metal spiral coil onto the mandrel. The rear rotary motor 3 drives the mandrel to rotate, enabling the metal spiral to continuously wind on the mandrel. The torque sensor 18 on the stretching pulley 12 continuously monitors the data during the subsequent winding process. At the same time, the spiral auxiliary feed pulley 28 is also equipped with a torque sensor. By monitoring the torque value on the spiral auxiliary feed pulley, the stress and tension of the metal spiral from the auxiliary stretching pulley 11 to the spiral auxiliary feed pulley 28 can be monitored. The torque value on the spiral auxiliary feed pulley 28 is transmitted to the computer and compared with the pulley torque value corresponding to the elastic deformation range of the spiral. This controls the rotation of the second pulley drive motor 16 on the auxiliary feed pulley 28, controlling the stretching and contraction of this part of the metal spiral, preventing the metal spiral from being stretched and formed, which would affect the subsequent fixed pitch stretching process. It also ensures that the metal spiral does not slip off the spiral auxiliary stretching pulley 28, ensuring the consistency of the metal and rubber.
[0061] The fourth step involves using a preset program to achieve dynamic coordination of the winding angle control during each process of the metal spiral winding with fixed pitch stretching and reciprocating motion.
[0062] When the rotary motor 3 rotates, the horizontal linear module on the gantry linear guide 10 also slides. By adjusting the sliding speed of the sliding base 15 on the horizontal linear module relative to the winding point on the spindle 8, the winding angle of the metal spiral coil in each reciprocating motion can be changed. The winding angle of each reciprocating motion is selected by the computer, and the displacement speed of the sliding base 15 is controlled by the PLC to keep the winding angle of each reciprocating motion within 50 degrees, with the direction away from the shearing disc device as the positive direction. When the forward limit is reached as set by the program, the rotating servo motor inside the sliding base 15 (not shown in the diagram) operates, driving the rotating bracket 13 to rotate and thus changing the winding direction of the metal spiral coil. When the return limit is reached as set by the program, its steering principle is the same as the forward stroke.
[0063] Through program control, the PLC controls the rotation of the pulley drive motor 16 and the movement of the sliding base 15 on the gantry linear module guide rail based on the comparison results returned by the computer, so that the monitored value on the torque sensor 18 remains consistent with the required value.
[0064] Fifth step: If you want to interrupt the winding process, you can use a preset program to interrupt the winding process.
[0065] The program is set so that, with the metal spiral coil partially wound around the mandrel, the pulley drive motor 21 drives the sprue clamp 19 back to its initial position. The slider on the vertical guide rail of the gantry linear module guide rail 10, which is connected to the horizontal linear module guide rail, is axially displaced. The sliding base 15 on the horizontal linear module is laterally displaced, so that the section of the metal spiral coil from the mandrel 8 to the tension pulley 12 on the pulley tensioning device 9 is exactly in the opening between the sprue clamp 19 and the pneumatic shear 23. Then, the sprue clamp 19 clamps the metal spiral coil, and then the pneumatic shear 23 cuts the metal spiral coil. At this point, the winding process is interrupted, and the mandrel can be directly removed. If the next winding is to be performed, the mandrel can be directly installed, the program can be run, and steps three and four can be repeated to start winding directly.
[0066] Step 6: The winding process is complete. End the winding.
[0067] The program is set so that during the winding process, the pulley drive motor 21 rotates to drive the sprue clamp 19 back to the initial position. Due to continuous winding, most of the metal spiral coil is wound on the mandrel 8, and the length of the spiral coil in the hopper 27 gradually decreases. Since the detection end of the tension sensor 29 is connected to the end of the metal spiral coil, when the tension sensor 29 is subjected to a tension greater than the program-set threshold, the rotary motor 3 and the pulley drive motor 16 stop running. The slider on the vertical guide rail of the gantry linear module guide rail 10, which is connected to the horizontal linear module guide rail, is axially displaced. The sliding base 15 on the horizontal linear module is laterally displaced, so that the section of the metal spiral coil from the mandrel 8 to the tension pulley 12 on the pulley tensioning device 9 is exactly in the opening between the sprue clamp 19 and the pneumatic shear 23. Then the sprue clamp 19 clamps, the pneumatic shear 23 cuts, and the mandrel 8 is removed. Finally, the metal rubber blank is prepared on the mandrel 8.
[0068] Compared with current equipment for producing metal-rubber blanks, the present invention has the following advantages:
[0069] Compared to existing technologies, this equipment optimizes and improves its mechanical structure, and through high electromechanical integration, it achieves precise control of the winding angle in each process of constant pitch stretching and reciprocating motion during the preparation of metal rubber blanks, thereby further improving the consistency and uniformity of the metal rubber.
[0070] Because this equipment dynamically controls the pitch stretching by transmitting data from a torque sensor to a computer in real time, its advantage is that it can more accurately control the fixed pitch stretching through real-time data monitoring.
[0071] Compared to current metal rubber blank production equipment, this equipment achieves fully automated metal rubber blank production while ensuring the consistency of metal rubber. It can also perform multiple preparations when the metal spiral roll length is sufficient, thereby improving the productivity of metal rubber blanks. At the same time, it can also meet the design and preparation of irregular and complex structures.
[0072] Compared to existing metal-rubber blank production equipment, this equipment has clearly defined functions for each module and is easy to assemble and disassemble.
Claims
1. A fully automated intelligent device for winding complex, irregularly shaped metal-rubber blanks, characterized in that, The device includes a worktable (6) and a fixed-pitch stretching device (2) located behind the worktable (6). The worktable (6) is equipped with a rotary motor (3) for controlling the rotation of the mandrel (8) and a shearing disc device (7) for clamping and shearing the metal spiral coil. The fixed-pitch stretching device (2) includes a pulley stretching device (9) and a gantry linear module guide rail (10) for driving the pulley stretching device (9) to move horizontally and vertically. A stand (1) is installed on the worktable (6) between the fixed-pitch stretching device (2) and the mandrel (8). The stand (1) is equipped with... There is a hopper (27) for placing the metal spiral coil and a spiral coil auxiliary feed pulley (28) for assisting in controlling the feeding of the metal spiral coil; the hopper (27) is equipped with a tension sensor (29) for monitoring the tension of the metal spiral coil; the gantry linear module guide rail consists of three linear module guide rails, of which two vertical linear module guide rails are placed on the rear side of the worktable and perpendicular to the worktable plane, and a pulley tensioning device (9) is placed on one of the horizontal linear module guide rails. The two ends of the horizontal linear module guide rail are connected to the sliders of the two vertical linear module guide rails to realize the horizontal linear module. The longitudinal movement of the guide rail causes the pulley tensioning device (9) to move laterally on the horizontal linear module guide rail; the pulley tensioning device (9) includes a rotating bracket (13), a tension pulley (12), an auxiliary tension pulley (11), a torque sensor (18) for monitoring pulley torque, a rectangular housing (17), a pulley drive motor (16) for driving the tension pulley to rotate, a rotating support (14), and a sliding base (15). The tension pulley (12) and the auxiliary tension pulley (11) are horizontally aligned and installed between two parallel rectangular housings (17), forming a U-shape. The rotating bracket (13) is fixed to the two rectangular shells (17) by bolts. The bottom of the rotating bracket (13) is connected to a rotating servo motor installed on the rotating support base (14). The rotating bracket (13) is driven to rotate by the rotating servo motor. Torque sensors (18) are installed on both the tension pulley (12) and the auxiliary tension pulley (11). A tension sensor (29) for detecting the tension at the end of the metal spiral coil is installed on the rear side of the hopper (27). A torque sensor (18) for monitoring the torque of the spiral coil auxiliary feed pulley (28) is also installed on the spiral coil auxiliary feed pulley (28).The shearing disc device (7) consists of a pulley drive motor (21), a rotating base (22), a rotating disc (20), a sprue clamp (19), a pneumatic shear (23), a synchronous belt (24), a small synchronous pulley (26), and a large synchronous pulley (25). The rotating disc has a shaft section, the end of which is connected to the large synchronous pulley (25). A hole is drilled at the bottom of the rotating base (22), and the output shaft of the pulley drive motor (21) at the bottom of the rotating base (22) is connected to the small synchronous pulley (26) through this hole. The transmission is connected, and the two pulleys are driven by a synchronous belt. The sprue clamp (19) and the pneumatic shear (23) are installed on the same radial line of the rotating disk (20), and the distance between the sprue clamp (19) and the center of the rotating disk (20) is greater than the distance between the pneumatic shear (23) and the center of the rotating disk (20). The initial position of the sprue clamp (19) and the pneumatic shear (23) is set when the radial line of the sprue clamp (19) and the pneumatic shear (23) is parallel to the worktable and close to the fixed pitch tensioning device (2). Both the sprue clamp and the pneumatic shear are pneumatically controlled.
2. The fully automatic intelligent device for winding complex metal-rubber blanks of irregularly shaped components according to claim 1, characterized in that, A platform (5) is placed below the rotary motor (3) so that the axis of the spindle (8) coincides with the axis of the rotating disk (20) when the rotary motor (3) is running.
3. The fully automatic intelligent device for winding complex metal-rubber blanks of irregularly shaped components according to claim 2, characterized in that, The tension sensor (29) is placed inside the hopper (27) through a hole on the rear side of the hopper (27), while the main body of the tension sensor (29) is installed on the rear side of the hopper.
4. The fully automatic intelligent device for winding complex metal-rubber blanks of irregularly shaped components according to claim 3, characterized in that, An electrical control cabinet (4) is provided on the side of the workbench (6).
5. The fully automatic intelligent device for winding complex metal-rubber blanks of irregularly shaped components according to claim 4, characterized in that, The spiral auxiliary feed pulley (28) is also connected to a second pulley drive motor that drives its rotation.
6. A method for operating the fully automated intelligent device for winding complex, irregularly shaped metal-rubber blanks as described in claim 5. The first step is to initialize the components in the device to their initial positions using the initialization procedure. The initialization program is used to put the sprue clamp (19) on the rotating disk (20) and the pneumatic shear (23) into their initial positions via the pulley drive motor (21). The second step is to first pass the metal spiral coil around the tension pulley (12), the auxiliary tension pulley (11), and the spiral coil auxiliary feed pulley (28). Place the metal spiral coil in the hopper (27), then connect and fix one end of the metal rubber spiral coil to the tension sensor (29), pull out the other end and wrap it around the upper groove of the auxiliary feeding pulley (28) and the lower groove of the auxiliary stretching pulley (11) one after the spiral coil, and finally wrap it out from the upper groove of the stretching pulley (12), and finally clamp it with the sprue clamp (19); The third step is to stretch the metal spiral coil to a fixed pitch using a preset program. At this time, the pulley drive motor (16) is controlled by the PLC in the electrical control cabinet (4) to drive the tension pulley (12) to rotate. When the tension pulley (12) on the pulley tensioning device (9) rotates, it drives the metal spiral coil to stretch or unwind. At the same time, the torque sensor (18) on the pulley tensioning device (9) monitors the torque of the tension pulley (12) in real time and transmits the data to the computer in the electrical control cabinet (4). The computer compares the value of its torque with the value of the torque required to stretch the 1.8 mm pitch, thereby adjusting the torque value. The comparison result is transmitted to the PLC, which then controls the forward and reverse rotation of the pulley drive motor (16). When the pulley drive motor (16) rotates forward, the tension on the metal spiral coil between the sprue clamp (19) and the tension pulley (12) decreases, and vice versa, thus stretching or shrinking the metal spiral coil. This controls the pitch of the metal spiral coil to be 1.8 mm. The pulley drive motor (21) drives the rotating disk (20) to rotate several times, thereby driving the sprue clamp (19) to rotate around the mandrel (8), thus stretching the metal spiral coil. The metal spiral is initially wound onto the mandrel, and then the rotating motor (3) drives the mandrel to rotate, so that the metal spiral is continuously wound on the mandrel. The torque sensor (18) on the stretching pulley (12) continuously monitors the data during the subsequent winding process. At the same time, the spiral auxiliary feed pulley (28) is also equipped with a torque sensor. By monitoring the torque value on the spiral auxiliary feed pulley, the force and tension of the metal spiral from the auxiliary stretching pulley (11) to the spiral auxiliary feed pulley (28) are monitored. At the same time, the torque value on the spiral auxiliary feed pulley (28) is transmitted to the computer and compared with the pulley torque value corresponding to the spiral within the range of elastic deformation. This controls the second pulley drive motor on the spiral auxiliary feed pulley (28) to rotate, controls the stretching and shrinking of this part of the metal spiral, prevents the metal spiral from being stretched and formed, and affects the subsequent fixed pitch stretching process. It also ensures that the metal spiral does not slip off the spiral auxiliary feed pulley (28) and ensures the consistency of the metal rubber. The fourth step involves using a preset program to achieve dynamic coordination of the winding angle control during each process of the metal spiral winding with fixed pitch stretching and reciprocating motion. When the rotary motor (3) rotates, the horizontal linear module guide rail on the gantry linear module guide rail (10) also slides. By adjusting the sliding speed of the sliding base (15) on the horizontal linear module guide rail relative to the winding point on the spindle (8), the winding angle of the metal spiral coil in each reciprocating motion is changed. The winding angle of each reciprocating motion is selected by the computer, and the displacement speed of the sliding base (15) is controlled by the PLC so that the winding angle of each reciprocating motion is controlled within 50 degrees. The direction away from the shearing disc device is taken as the positive direction. When the forward limit is reached, the rotating servo inside the sliding base (15) operates, driving the rotating bracket (13) to rotate, thereby changing the winding direction of the metal spiral coil. When the return limit is reached, its turning principle is the same as the forward stroke. Through program control, the PLC controls the rotation of the pulley drive motor (16) and the movement of the sliding base (15) on the gantry linear module guide rail by the comparison results returned by the computer, so that the monitored value on the torque sensor (18) is consistent with the required value. Fifth step: If you want to interrupt the winding process, you can use a preset program to interrupt the winding process; The program is set such that, under the premise that the metal spiral coil has been partially wound around the mandrel, the pulley drive motor (21) drives the sprue clamp (19) back to the initial position, the slider on the vertical linear module guide rail (10) of the gantry linear module guide rail (10) connected to the horizontal linear module guide rail is axially displaced, and the sliding base (15) on the horizontal linear module guide rail is laterally displaced, so that the metal spiral coil from the mandrel (8) to the tension pulley (12) on the pulley tensioning device (9) is exactly in the opening between the sprue clamp (19) and the pneumatic shear (23). Then the sprue clamp (19) clamps the metal spiral coil, and then the pneumatic shear (23) cuts the metal spiral coil. At this time, the winding process is interrupted, and the mandrel can be taken out directly. If the next winding is to be carried out, the mandrel can be installed directly, the program can be run, and the third and fourth steps can be repeated to start winding directly. Step 6: The winding process is complete; end the winding. The program is set so that during the winding process, the pulley drive motor (21) rotates to drive the sprue clamp (19) back to the initial position. Due to continuous winding, most of the metal spiral coil is wound on the mandrel (8), and the length of the spiral coil in the hopper (27) gradually decreases. Since the detection end of the tension sensor (29) is connected to the end of the metal spiral coil, when the tension sensor (29) is subjected to a tension greater than the program-set threshold, the rotary motor (3) and the pulley drive motor (16) stop running, and the gantry linear module guide rail (1) stops. The slider connected to the horizontal linear module guide rail on the vertical linear module guide rail of 0) is axially displaced and adjusted. The sliding base (15) on the horizontal linear module guide rail is laterally displaced and adjusted so that the metal spiral coil from the mandrel (8) to the tension pulley (12) on the pulley tensioning device (9) is exactly in the opening of the sprue clamp (19) and the pneumatic shear (23). Then the sprue clamp (19) clamps and the pneumatic shear (23) cuts and removes the mandrel (8). Finally, the metal rubber blank is prepared on the mandrel (8).