An intelligent assembly system for railway car brake valves

Abstract

The present application belongs to the technical field of brake valve assembly, and particularly relates to an intelligent assembly system for railway freight car brake valves, comprising a machine body, a main valve displacement unit, an emergency valve clamping unit and a tightening gun unit are installed on the machine body; the main valve displacement unit comprises a base fixed on the machine body, a tilting driving mechanism is installed on the base, an output end of the tilting driving mechanism is connected with a rotary arm, a rotary driving mechanism is installed on the rotary arm, an output end of the rotary driving mechanism is connected with a rotary base, and a main valve clamping mechanism is installed on the rotary base; the emergency valve clamping unit is fixed on the lower side of a workbench, a moving driving unit is directly installed on the lower side of the workbench, an output end of the moving driving unit is connected with a moving plate, and an emergency valve clamping mechanism is installed on one end of the moving plate. The present application provides an intelligent assembly system for railway freight car brake valves, which reduces manual operation and improves assembly efficiency and consistency.

Description

Technical Field

[0001] This invention belongs to the field of brake valve assembly technology, and specifically relates to an intelligent assembly system for brake valves of railway freight cars. Background Technology

[0002] Currently, the assembly of the 120 / 120-1 main valve and emergency valve is done manually. During assembly, the process must be followed according to the following steps: Keep the valve body with the mounting surface facing upwards. Inject a measured amount of silicone oil into the valve body components and then install the other components. Apply silicone grease to the valve body mounting surface and then install the valve cover along the double-ended studs onto the main valve body mounting surface. Finally, tighten the nuts with a torque wrench. Repeat the above steps to complete the installation of all four sides of the valve body; the main valve body assembly is now complete.

[0003] This production method suffers from problems such as high manual labor intensity, inability to record nut tightening torque and other assembly data, missing parts, incorrect or missing nuts, and lack of process control. Furthermore, manual valve body flipping and the lack of valve body securing during assembly pose a safety risk of falling and injuring personnel. As business grows and scales up, effectively recording nut tightening torque data during valve body assembly, preventing missed or incorrect nuts, and improving assembly efficiency while reducing safety risks have become increasingly important. Summary of the Invention

[0004] In order to solve the above-mentioned problems in the prior art, the purpose of this invention is to provide an intelligent assembly system for railway freight car brake valves that reduces manual operation, improves assembly efficiency and consistency.

[0005] The technical solution adopted in this invention is as follows:

[0006] An intelligent assembly system for railway freight car brake valves includes a body on which a main valve positioning unit, an emergency valve clamping unit, and a tightening gun unit are mounted. The main valve positioning unit includes a base fixed to the body, a tilting drive mechanism mounted on the base, a rotating arm connected to the output end of the tilting drive mechanism, a rotary drive mechanism mounted on the rotating arm, a rotary base connected to the output end of the rotary drive mechanism for placing the main valve, and a main valve clamping mechanism mounted on the rotary base. The output end of the rotary drive mechanism is perpendicular to the output end of the tilting drive mechanism. The emergency valve clamping unit includes a worktable fixed to the body, a moving drive unit mounted under the worktable, a moving plate connected to the output end of the moving drive unit, and an emergency valve clamping mechanism mounted at one end of the moving plate for clamping the emergency valve.

[0007] The tilting drive mechanism of this invention can drive the rotating arm to rotate, thereby causing the rotating arm to tilt the slewing base and the main valve in the vertical plane. The slewing drive mechanism can drive the slewing base to rotate in the horizontal plane, thereby allowing the main valve to adjust its direction in the horizontal plane. Since the output end of the slewing drive mechanism is perpendicular to the output end of the tilting drive mechanism, the main valve can be adjusted to various directions, facilitating the assembly of each side of the main valve and avoiding manual flipping of the main valve. After the main valve is placed on the slewing base, the main valve clamping mechanism can clamp the main valve, preventing loosening during the assembly of the main valve.

[0008] The movable drive mechanism of this invention can push out or retract the movable plate. When the movable plate is retracted, it can prevent the movable plate from obstructing other valve bodies during assembly. The emergency valve clamping mechanism can clamp the emergency valve, ensuring that the emergency valve is reliably fixed and facilitating the assembly of the emergency valve.

[0009] The tightening gun unit features data transmission, nut sequence determination, and alarm functions. It determines the tightening position of each nut based on encoder values; if the tightening sequence is incorrect, an alarm sounds. It automatically records the nut tightening data, issuing warnings if any torque is unacceptable, reducing rework rates and improving product quality. After assembly, the system automatically uploads the stored tightening torque data to the server system, ensuring traceability by matching it with all detected parameters.

[0010] This invention changes the current production model, significantly reducing reliance on human labor while improving the standardization of process and quality management, thus enhancing product consistency. The invention employs a mechanical self-locking clamping mechanism and automatic flipping technology to avoid the risk of operators accidentally dropping and injuring themselves, thereby improving production safety.

[0011] In a preferred embodiment of the present invention, two blocking buffers are installed on the base, and the two blocking buffers are respectively disposed on both sides of the rotating arm, with the blocking surfaces of the two blocking buffers being perpendicular. The blocking buffers on both sides can limit the rotation of the rotating arm. When the rotating arm rotates to contact the lower blocking buffer, the rotating base is horizontal; when the rotating arm rotates to contact the upper blocking buffer, the rotating base is vertical.

[0012] In a preferred embodiment of the present invention, the rotary drive mechanism includes a rotary drive motor mounted on a rotating arm. A drive gear is mounted at the output end of the rotary drive motor, and the drive gear meshes with a driven gear. The driven gear is rotatably connected to the rotating arm, and a rotary base is connected to the driven gear. When the rotary drive motor drives the drive gear to rotate, the drive gear drives the driven gear to rotate, and the driven gear drives the rotary base to rotate, facilitating the rotation of the main valve to a suitable direction.

[0013] In a preferred embodiment of the present invention, the rotary base includes a support plate connected to the output end of the rotary drive mechanism. A frame is fixed on the support plate, and a tooling base plate for placing the main valve is fixed on the frame. The main valve clamping mechanism includes a clamping cylinder mounted on the rotating arm. A spherical bearing is connected to the piston rod of the clamping cylinder, and a lifting block is connected to the spherical bearing. A connecting rod is hinged to the lifting block, and a pushing block is hinged to the other end of the connecting rod. A main valve chuck for clamping the main valve is rotatably connected to the tooling base plate. One end of the main valve chuck is provided with a pushing elongated hole, and a push rod is provided on the pushing block, with the push rod sleeved in the pushing elongated hole.

[0014] When the clamping cylinder drives the push block to rise and fall, the push block drives the connecting rod to move, which in turn drives the push block to move. The push rod on the push block pushes the main valve chuck to tilt. After the main valve chuck tilts, it can clamp the main valve, achieving reliable clamping of the main valve.

[0015] In a preferred embodiment of the present invention, a linear guide rail is provided on the lower side of the tooling base plate, and a sliding block is fixed on the push block, the sliding block being sleeved on the linear guide rail. The sliding block always slides on the linear guide rail, thereby pushing the block to move linearly, ensuring that the push rod on the push block is ready to push the main valve clamp to tilt.

[0016] In a preferred embodiment of the present invention, the moving drive mechanism includes a fixed guide rail fixed to the lower side of the worktable, a plurality of movable sliders sleeved on the fixed guide rail, the movable sliders being fixed to the moving plate, and a guide rail cylinder also being installed on the lower side of the worktable, the cylinder slider of the guide rail cylinder being fixed to the moving plate. During the movement of the moving plate, the movable sliders on the moving plate always slide on the fixed guide rail, improving the stability of the moving plate during movement.

[0017] In a preferred embodiment of the present invention, the emergency valve clamping mechanism includes a telescopic cylinder mounted on a movable plate. A telescopic head is fixed to the piston rod of the telescopic cylinder. The telescopic head is rotatably connected to a rod plate and a linkage rod. A fixed head is fixed to the cylinder barrel of the telescopic cylinder. A rocker arm is rotatably connected to the fixed head. The end of the linkage rod away from the telescopic head is rotatably connected to the middle section of the rocker arm. An emergency valve clamp for clamping the emergency valve is rotatably connected to the end of the rod plate away from the telescopic head. The end of the rocker arm away from the fixed head is rotatably connected to the middle section of the emergency valve clamp. During the process of the piston rod of the telescopic cylinder pushing out the telescopic head, the rocker arm, rod plate, and linkage rod move, pushing the emergency valve clamp to tilt, so that the emergency valve clamp can rotate to the position of clamping the emergency valve.

[0018] As a preferred embodiment of the present invention, the tightening gun unit includes a central guide rod rotatably connected to the machine body, a linear bearing sleeved on the central guide rod, a first rotating arm fixed on the linear bearing, a second rotating arm rotatably connected to the other end of the first rotating arm, and a tightening gun installed on the other end of the second rotating arm; an encoder is installed on the shaft between the central guide rod, the first rotating arm, and the second rotating arm.

[0019] The first rotating arm rotates with the central guide rod, and the second rotating arm can rotate relative to the first rotating arm, thus allowing the tightening gun to be pulled to any position within a certain area, facilitating the assembly of the main valve or emergency valve. The tightening position of each nut is determined based on the values ​​of the two encoders; if the tightening sequence is incorrect, an alarm will sound.

[0020] In a preferred embodiment of the present invention, a support frame is fixed on the central guide rod, and a balancer is installed on the support frame. The balancer is connected to the linear bearing via a rope. The balancer enables the linear bearing to suspend, thereby saving effort.

[0021] As a preferred embodiment of the present invention, the workbench is further provided with a silicone grease box, which is connected to a metering oil injection mechanism. Metering the silicone oil by the metering oil injection mechanism reduces the problem of manual application of too much or too little silicone oil.

[0022] The beneficial effects of this invention are as follows:

[0023] 1. The tilting drive mechanism of the present invention can drive the rotating arm to rotate, thereby causing the rotating arm to tilt the slewing base and the main valve in the vertical plane. The slewing drive mechanism can drive the slewing base to rotate in the horizontal plane, thereby allowing the main valve to adjust its direction in the horizontal plane. Since the output end of the slewing drive mechanism is perpendicular to the output end of the tilting drive mechanism, the main valve can be adjusted to various directions, facilitating the assembly of each side of the main valve and avoiding manual flipping of the main valve. After the main valve is placed on the slewing base, the main valve clamping mechanism can clamp the main valve, preventing loosening during the assembly of the main valve.

[0024] 2. The moving drive mechanism of the present invention can push out or retract the moving plate. When the moving plate is retracted, it can prevent the moving plate from obstructing other valve bodies during assembly. The emergency valve clamping mechanism can clamp the emergency valve, ensuring that the emergency valve is reliably fixed and facilitating the assembly of the emergency valve.

[0025] 3. The tightening gun unit features data transmission, nut sequence determination, and alarm functions. It determines the tightening position of each nut based on encoder values; if the tightening sequence is incorrect, an alarm sounds. It automatically records the nut tightening data, issuing warnings if any torque is unacceptable, reducing rework rates and improving product quality. After assembly, the system automatically uploads the stored tightening torque data to the server system, ensuring traceability by matching it with all detected parameters.

[0026] 4. This invention changes the current production model, significantly reducing reliance on human labor while improving the standardization of process management and quality management, thus enhancing product consistency. The invention employs a mechanical self-locking clamping mechanism and automatic flipping technology, avoiding the risk of operators accidentally dropping and injuring themselves, thereby improving production safety. Attached Figure Description

[0027] Figure 1 This is a schematic diagram of the structure of the present invention;

[0028] Figure 2 This is a partial structural diagram of the main valve displacement unit;

[0029] Figure 3 This is the front view of the main valve displacement unit;

[0030] Figure 4 This is a partial structural diagram of the main valve clamping mechanism in the clamping state;

[0031] Figure 5 This is the front view of the main valve clamping mechanism in the clamping state;

[0032] Figure 6 This is a partial structural diagram of the main valve clamping mechanism in the open state;

[0033] Figure 7 This is a front view of the main valve clamping mechanism in the open state;

[0034] Figure 8 This is a schematic diagram of the emergency valve clamping unit;

[0035] Figure 9 This is the front view of the emergency valve clamping unit;

[0036] Figure 10 This is a schematic diagram of the emergency valve clamping unit in the released state;

[0037] Figure 11 This is a schematic diagram of the emergency valve clamping unit in the clamping state;

[0038] Figure 12 This is a top view of the emergency valve clamping unit in the released state;

[0039] Figure 13 This is a top view of the emergency valve clamping unit in the clamped state;

[0040] Figure 14 This is a schematic diagram of the emergency valve clamping mechanism;

[0041] Figure 15 This is a structural diagram of the tightening gun unit in the open state;

[0042] Figure 16 This is a structural diagram of the tightening gun unit in its retracted state.

[0043] In the diagram: 1-Main body; 2-Main valve positioner; 3-Emergency valve clamping unit; 4-Tightening gun unit; 11-Silicone grease box; 12-Quantitative oil injection mechanism; 13-Industrial control integrated computer; 14-RFID reader; 15-Headpiece box; 16-Pneumatic button box; 17-Workbench; 21-Base; 22-Tilting drive mechanism; 23-Rotating arm; 24-Slewing drive mechanism; 25-Slewing base; 26-Main valve clamping mechanism; 31-Moving drive mechanism; 32-Moving plate; 33-Emergency valve clamping mechanism; 41-Center guide rod; 42-Linear bearing; 43-First rotating arm; 44-Second rotating arm; 45-Tightening gun; 46-Encoder; 47-Support frame; 48-Balancer; 49-Anti-rotation rod; 211-Blocking buffer; 241-Slewing drive motor; 242-Drive gear ; 243-Driven gear; 244-Tensioning mechanism; 251-Support plate; 252-Frame; 253-Tooling base plate; 254-Guide hole; 255-Main valve sensor; 256-Main valve positioning pin; 261-Clamping cylinder; 262-Spherical bearing; 263-Lifting block; 264-Connecting rod; 265-Push block; 266-Main valve chuck; 267-Linear guide rail; 268-Sliding block; 269-Guide column; 311-Guide rail cylinder; 312-Fixed guide rail; 313-Moving slider; 321-Panel; 322-Mounting groove; 323-Emergency valve positioning pin; 324-Occupancy sensor; 331-Telescopic cylinder; 332-Telescopic head; 333-Rod; 334-Linkage rod; 335-Fixed head; 336-Swing rod; 337-Emergency valve chuck; 338-Pressure head. Detailed Implementation

[0044] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0045] Therefore, the following detailed description of the embodiments of the invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the invention without inventive effort are within the scope of protection of the invention. It should be noted that, unless otherwise specified, the embodiments and features described in the embodiments of the invention can be combined with each other.

[0046] like Figure 1As shown, the intelligent assembly system for railway freight car brake valves in this embodiment includes a body 1, on which a main valve displacement unit 2, an emergency valve clamping unit 3, and a tightening gun unit 4 are mounted. The main valve displacement unit 2 includes a base 21 fixed to the body 1, a tilting drive mechanism 22 mounted on the base 21, a rotating arm 23 connected to the output end of the tilting drive mechanism 22, a rotary drive mechanism 24 mounted on the rotating arm 23, a rotary base 25 for placing the main valve connected to the output end of the rotary drive mechanism 24, and a main valve clamping mechanism 26 mounted on the rotary base 25. The output end of the rotary drive mechanism 24 is perpendicular to the output end of the tilting drive mechanism 22. The emergency valve clamping unit 3 includes a workbench 17 fixed to the body 1, a moving drive unit mounted on the lower side of the workbench 17, a moving plate 32 connected to the output end of the moving drive unit, and an emergency valve clamping mechanism 33 for clamping the emergency valve mounted on one end of the moving plate 32.

[0047] The tilting drive mechanism 22 of this invention can drive the rotating arm 23 to rotate, thereby causing the rotating arm 23 to tilt the slewing base 25 and the main valve in the vertical plane. The slewing drive mechanism 24 can drive the slewing base 25 to rotate in the horizontal plane, thereby allowing the main valve to adjust its direction in the horizontal plane. Since the output end of the slewing drive mechanism 24 is perpendicular to the output end of the tilting drive mechanism 22, the main valve can be adjusted in various directions, facilitating the assembly of each side of the main valve and avoiding manual flipping of the main valve. After the main valve is placed on the slewing base 25, the main valve clamping mechanism 26 can clamp the main valve, preventing loosening during assembly. The tilting drive mechanism 22 is a servo geared motor.

[0048] The movable drive mechanism 31 of the present invention can push out or retract the movable plate 32. When the movable plate 32 is retracted, it can prevent the movable plate 32 from obstructing other valve bodies during assembly. The emergency valve clamping mechanism 33 can clamp the emergency valve, ensuring that the emergency valve is reliably fixed and facilitating the assembly of the emergency valve.

[0049] The tightening gun unit 4 features data transmission, nut sequence determination, and alarm functions. It determines the tightening position of each nut based on the encoder 46 value; if the tightening sequence is incorrect, an alarm sounds. It automatically records the nut tightening data, issuing warnings if any torque is unacceptable, reducing rework rates and improving product quality. After assembly, the system automatically uploads the stored tightening torque data to the server system, ensuring traceability by matching it with all detected parameters.

[0050] This invention changes the current production model, significantly reducing reliance on human labor while improving the standardization of process and quality management, thus enhancing product consistency. The invention employs a mechanical self-locking clamping mechanism and automatic flipping technology to avoid the risk of operators accidentally dropping and injuring themselves, thereby improving production safety.

[0051] like Figures 2-7 As shown, in order to position the rotating arm 23, two blocking buffers 211 are installed on the base 21. The two blocking buffers 211 are respectively located on both sides of the rotating arm 23, and the blocking surfaces of the two blocking buffers 211 are vertical. The blocking buffers 211 on both sides can limit the rotation of the rotating arm 23. When the rotating arm 23 rotates to contact the lower blocking buffer 211, the rotating base 25 is horizontal. When the rotating arm 23 rotates to contact the upper blocking buffer 211, the rotating base 25 is vertical.

[0052] Specifically, the rotary drive mechanism 24 includes a rotary drive motor 241 mounted on the rotating arm 23. A drive gear 242 is mounted on the output end of the rotary drive motor 241. The drive gear 242 meshes with a driven gear 243, which is rotatably connected to the rotating arm 23. A rotary base 25 is connected to the driven gear 243. When the rotary drive motor 241 drives the drive gear 242 to rotate, the drive gear 242 drives the driven gear 243 to rotate, and the driven gear 243 drives the rotary base 25 to rotate, facilitating the rotation of the main valve to the appropriate direction.

[0053] The rotary drive mechanism 24 also includes a tensioning mechanism 244. The rotary drive motor 241 is mounted on the tensioning mechanism 244. The tensioning mechanism 244 is provided with an adjustment elongated hole, which is connected to the rotating arm 23 by bolts. The tensioning mechanism 244 can be adjusted in position by adjusting the adjustment elongated hole, thereby adjusting the gap between the driving gear 242 and the driven gear 243.

[0054] The rotary base 25 includes a support plate 251, which is connected to the output end of the rotary drive mechanism 24. A frame 252 is fixed on the support plate 251, and a tooling base plate 253 for placing the main valve is fixed on the frame 252. The main valve clamping mechanism 26 includes a clamping cylinder 261 mounted on the rotating arm 23. A spherical bearing 262 is connected to the piston rod of the clamping cylinder 261. A lifting block 263 is connected to the spherical bearing 262. A connecting rod 264 is hinged to the lifting block 263, and a push block 265 is hinged to the other end of the connecting rod 264. A main valve chuck 266 for clamping the main valve is rotatably connected to the tooling base plate 253. One end of the main valve chuck 266 is provided with a push elongated hole, and a push rod is provided on the push block 265, which is sleeved in the push elongated hole.

[0055] When the clamping cylinder 261 drives the push block 265 to rise or fall, the push block 265 drives the connecting rod 264 to move, and the connecting rod 264 drives the push block 265 to move. The push rod on the push block 265 pushes the main valve chuck 266 to tilt. After the main valve chuck 266 tilts, it can clamp the main valve, realizing reliable clamping of the main valve.

[0056] A linear guide rail 267 is provided on the lower side of the tooling base plate 253. A sliding block 268 is fixed on the push block 265 and is sleeved on the linear guide rail 267. The sliding block 268 always slides on the linear guide rail 267, thereby pushing the block 265 to move linearly, ensuring that the push rod on the push block 265 is ready to push the main valve chuck 266 to tilt.

[0057] A guide post 269 is fixed on the lifting block 263, and a guide hole 254 is provided on the tooling base plate 253. The guide post 269 is inserted into the guide hole 254. During the lifting process of the lifting block 263, the guide hole 254 guides the guide post 269 to ensure that the lifting block 263 lifts and lowers smoothly.

[0058] A main valve sensor 255 is installed on the tooling base plate 253 to detect whether a main valve is placed on it. The main valve sensor 255 can detect whether a main valve is placed on the tooling base plate 253.

[0059] The tooling base plate 253 is provided with a main valve positioning pin 256 for cooperating with the main valve. The main valve positioning pin 256 is inserted into a hole on the main valve to position the main valve.

[0060] like Figures 8-14 As shown, the moving drive mechanism 31 includes a fixed guide rail 312 fixed to the lower side of the worktable 17. Several movable sliders 313 are sleeved on the fixed guide rail 312 and fixed to the moving plate 32. A guide rail cylinder 311 is also installed on the lower side of the worktable 17, and the cylinder slider of the guide rail cylinder 311 is fixed to the moving plate 32. During the movement of the moving plate 32, the movable sliders 313 on the moving plate 32 always slide on the fixed guide rail 312, improving the stability of the moving plate 32 during movement. There are two fixed guide rails 312, which are respectively located on both sides of the moving plate 32.

[0061] Specifically, the emergency valve clamping mechanism 33 includes a telescopic cylinder 331 mounted on a movable plate 32. A telescopic head 332 is fixed to the piston rod of the telescopic cylinder 331. The telescopic head 332 is rotatably connected to a rod 333 and a linkage rod 334. A fixed head 335 is fixed to the cylinder of the telescopic cylinder 331. A rocker arm 336 is rotatably connected to the fixed head 335. The end of the linkage rod 334 away from the telescopic head 332 is rotatably connected to the middle section of the rocker arm 336. The end of the rod 333 away from the telescopic head 332 is rotatably connected to an emergency valve clamp 337 for clamping the emergency valve. The end of the rocker arm 336 away from the fixed head 335 is rotatably connected to the middle section of the emergency valve clamp 337. During the process of the piston rod of the telescopic cylinder 331 pushing the telescopic head 332 out, the rocker arm 336, the rod 333, and the linkage rod 334 move, pushing the emergency valve clamp 337 to tilt, so that the emergency valve clamp 337 can rotate to the position of pressing the emergency valve. A pressure head 338 is fixed on the emergency valve clamp 337. The pressure head 338 can increase the contact area between the emergency valve and the clamping stability.

[0062] There are two emergency valve clamping mechanisms 33, which are respectively located on both sides of the movable plate 32.

[0063] The movable plate 32 is provided with a panel 321 and a mounting groove 322. The emergency valve clamping mechanism 33 is installed in the mounting groove 322, and the output end of the emergency valve clamping mechanism 33 extends out from the panel 321.

[0064] A locating pin is fixed on the panel 321 for engaging with the emergency valve. The locating pin is inserted into the hole of the emergency valve, thereby positioning the emergency valve.

[0065] The panel 321 is equipped with a position sensor 324 for detecting whether the emergency valve is in place. The position sensor 324 can detect whether the emergency valve is installed in place.

[0066] like Figure 15 and Figure 16 As shown, the tightening gun unit 4 includes a central guide rod 41 rotatably connected to the body 1, a linear bearing 42 sleeved on the central guide rod 41, a first rotating arm 43 fixed on the linear bearing 42, a second rotating arm 44 rotatably connected to the other end of the first rotating arm 43, and a tightening gun 45 installed on the other end of the second rotating arm 44; an encoder 46 is installed on the rotating shaft between the central guide rod 41, the first rotating arm 43 and the second rotating arm 44.

[0067] The first rotating arm 43 rotates with the central guide rod 41, and the second rotating arm 44 can rotate relative to the first rotating arm 43, thereby allowing the tightening gun 45 to be pulled to any position within a certain area, facilitating the assembly of the main valve or emergency valve. The tightening position of each nut is determined based on the values ​​of the two encoders 46. If the tightening sequence is incorrect, an alarm will sound.

[0068] A support frame 47 is fixed to the central guide rod 41, and a balancer 48 is installed on the support frame 47. The balancer 48 is connected to the linear bearing 42 via a rope. An anti-rotation rod 49 is also connected to the support frame 47. The balancer 48 enables the linear bearing 42 to suspend, achieving the purpose of saving effort.

[0069] Furthermore, the workbench 17 is also equipped with a silicone grease box 11, which is connected to a metering oil injection mechanism 12. Metering the silicone grease through the metering oil injection mechanism 12 reduces the problem of applying too much or too little silicone grease manually. The machine body 1 is also equipped with an industrial control integrated computer 13, an RFID reader 14, a grease box 15, and a pneumatic button box 16.

[0070] The assembly process for the 120 / 120-1 main valve is as follows: The valve body is manually placed into the positioner fixture. RFID data is read and entered into the system. A measured amount of silicone oil is injected into the slide valve and it is then installed into the valve body. Other components are installed into the valve body. Silicone grease is applied to the valve body mounting surface. The valve cover is inserted along the studs. Tightening gun unit 4 determines the tightening sequence and quantity (an alarm will sound if the sequence is incorrect or if any parts are missed or incorrectly tightened). Tightening gun unit 4 provides feedback on the tightening torque. The industrial control integrated computer 13 records the tightening data of the top cover surface. The positioner switches the valve body mounting surface to another surface. The above installation steps are repeated until all four surfaces of the valve body are assembled, at which point the workpiece is released.

[0071] The assembly process for the emergency valve is as follows: The system is manually switched. The system determines that the positioner is at zero and there is no 120 main valve. The emergency valve mounting mechanism extends, and the valve body is manually inserted. RFID data is read and entered into the system. The parts are loaded into the valve body, and silicone grease is applied to the valve body mounting surface. The valve cover is inserted along the studs. Tightening gun unit 4 determines the tightening sequence and quantity (an alarm will sound if the sequence is incorrect or if there are any omissions or errors). Tightening gun unit 4 provides feedback on the tightening torque. The industrial control all-in-one computer 13 records the tightening data for the upper cover. The operator then switches to the lower cover. The above installation steps are repeated until the valve body is fully assembled, at which point the workpiece is released.

[0072] Working principle: After one side of the valve body is assembled, a manual instruction is given, and the industrial control all-in-one computer 13 interacts with the positioner to complete the assisted flipping. Then, the manual assembly of the other sides of the components is completed. All operations are performed by manually picking up the workpieces, applying silicone oil to the specified positions of the components, assembling them onto the valve body, and then completing the torque setting of the nuts. After assembly, the components are placed on the conveyor line to enter the next station.

[0073] The tightening gun unit 4 features data transmission, nut sequence determination, and alarm functions. It determines the tightening position of each nut based on the encoder 46 value; if the tightening sequence is incorrect, an alarm sounds. It automatically records the nut tightening data, issuing a warning if any torque is unacceptable, reducing rework rates and improving product quality. Precise silicone oil metering reduces the problem of manual application of too much or too little silicone oil.

[0074] After assembly, the system automatically uploads the stored tightening torque data to the server system, which corresponds one-to-one with the various parameters detected, ensuring traceability.

[0075] This invention changes the current production model, significantly reducing reliance on human labor, while improving the standardization of process management and quality management, thereby enhancing product consistency.

[0076] This invention improves production safety by using a mechanical self-locking clamping mechanism and automatic flipping technology to avoid the risk of the valve body accidentally falling and injuring the operator.

[0077] In summary, this invention employs a PLC automatic control design, which can automatically complete the flipping and rotation actions of each surface during product assembly and can feed data back to the industrial control integrated computer 13 to achieve data interaction; it is equipped with one electric torque wrench (tightening gun 45) for tightening M10 and M12 nuts, with torque requirements of 30±6 N·m and 50±10 N·m respectively. The two different torque values ​​can be quickly switched and error prevention is provided; the specified amount of silicone oil is sprayed out in a single meter using compressed air and a solenoid valve; a tool monitoring function is set to facilitate checking the standardization of operation; and a torque wrench position monitoring function is set to facilitate monitoring the tightening sequence of nuts.

[0078] This invention is not limited to the above-described optional embodiments. Anyone can derive other various forms of products under the guidance of this invention. However, regardless of any changes made in their shape or structure, any technical solution that falls within the scope of the claims of this invention shall be protected by this invention.

Claims

1. An intelligent assembly system for a railway freight car brake valve, characterized in that: The system includes a body (1), on which a main valve positioner unit (2), an emergency valve clamping unit (3), and a tightening gun unit (4) are mounted. The main valve positioner unit (2) includes a base (21) fixed to the body (1), a tilting drive mechanism (22) mounted on the base (21), a rotating arm (23) connected to the output end of the tilting drive mechanism (22), a rotary drive mechanism (24) mounted on the rotating arm (23), and a device for releasing... The main valve is mounted on a rotating base (25), and a main valve clamping mechanism (26) is installed on the rotating base (25). The output end of the rotating drive mechanism (24) is perpendicular to the output end of the tilting drive mechanism (22). The emergency valve clamping unit (3) includes a worktable (17) fixed on the machine body (1). A moving drive unit is installed on the lower side of the worktable (17). The output end of the moving drive unit is connected to a moving plate (32). An emergency valve clamping mechanism (33) is installed on one end of the moving plate (32). The rotary base (25) includes a support plate (251), which is connected to the output end of the rotary drive mechanism (24). A frame (252) is fixed on the support plate (251), and a tooling base plate (253) for placing the main valve is fixed on the frame (252). The main valve clamping mechanism (26) includes a clamping cylinder (261) mounted on the rotating arm (23). A joint shaft is connected to the piston rod of the clamping cylinder (261). A lifting block (263) is connected to the spherical bearing (262), and a connecting rod (264) is hinged to the lifting block (263). A push block (265) is hinged to the other end of the connecting rod (264). A main valve chuck (266) for clamping the main valve is rotatably connected to the tooling base plate (253). A push elongated hole is provided at one end of the main valve chuck (266), and a push rod is provided on the push block (265). The push rod is sleeved in the push elongated hole. The emergency valve clamping mechanism (33) includes a telescopic cylinder (331) mounted on a movable plate (32). A telescopic head (332) is fixed on the piston rod of the telescopic cylinder (331). The telescopic head (332) is rotatably connected to a rod (333) and a linkage rod (334). A fixed head (335) is fixed on the cylinder of the telescopic cylinder (331). A swing rod (336) is rotatably connected to the fixed head (335). The end of the linkage rod (334) away from the telescopic head (332) is rotatably connected to the middle section of the swing rod (336). The end of the rod (333) away from the telescopic head (332) is rotatably connected to an emergency valve chuck (337) for clamping the emergency valve. The end of the swing rod (336) away from the fixed head (335) is rotatably connected to the middle section of the emergency valve chuck (337). The tightening gun unit (4) includes a central guide rod (41) rotatably connected to the body (1), a linear bearing (42) sleeved on the central guide rod (41), a first rotating arm (43) fixed on the linear bearing (42), a second rotating arm (44) rotatably connected to the other end of the first rotating arm (43), and a tightening gun (45) installed on the other end of the second rotating arm (44); an encoder (46) is installed on the shaft between the central guide rod (41), the first rotating arm (43) and the second rotating arm (44).

2. The intelligent assembly system for a railway freight car brake valve according to claim 1, characterized in that: Two blocking buffers (211) are installed on the base (21). The two blocking buffers (211) are located on both sides of the rotating arm (23), and the blocking surfaces of the two blocking buffers (211) are perpendicular.

3. The intelligent assembly system for a railway freight car brake valve according to claim 1, characterized in that: The rotary drive mechanism (24) includes a rotary drive motor (241) mounted on a rotating arm (23). A drive gear (242) is mounted on the output end of the rotary drive motor (241). The drive gear (242) meshes with a driven gear (243). The driven gear (243) is rotatably connected to the rotating arm (23). The rotary base (25) is connected to the driven gear (243).

4. The intelligent assembly system for a railway freight car brake valve according to claim 1, characterized in that: A linear guide rail (267) is provided on the lower side of the tooling base plate (253), and a sliding block (268) is fixed on the push block (265). The sliding block (268) is sleeved on the linear guide rail (267).

5. The intelligent assembly system for a railway freight car brake valve according to claim 1, characterized in that: The moving drive mechanism (31) includes a fixed guide rail (312) fixed to the lower side of the worktable (17), and a number of movable sliders (313) are sleeved on the fixed guide rail (312). The movable sliders (313) are fixed to the moving plate (32). A guide rail cylinder (311) is also installed on the lower side of the worktable (17). The cylinder slider of the guide rail cylinder (311) is fixed to the moving plate (32).

6. The intelligent assembly system for a railway freight car brake valve according to claim 1, characterized in that: A support frame (47) is fixed on the central guide rod (41), and a balancer (48) is installed on the support frame (47). The balancer (48) is connected to the linear bearing (42) by a rope.

7. An intelligent assembly system for a railway freight car brake valve according to any one of claims 1 to 6, characterized in that: The workbench (17) is also equipped with a silicone grease box (11), and the silicone grease box (11) is connected to a metering oil injection mechanism (12).

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