Large bridge crane wheel automatic forging machining rotary table and machining method thereof

Abstract

The invention discloses a large bridge crane wheel automatic forging machining rotary table and a machining method thereof, a rotary table mechanism for forging machining, step-by-step forging dies, a power mechanism and an air cylinder jacking mechanism are included, the power mechanism drives the rotary table mechanism to rotate, and the step-by-step forging dies are evenly arranged on the rotary table mechanism; the air cylinder jacking mechanism is used for jacking the crane wheel in forging and is matched with a mechanical arm and a forging hammer of air forging, and automatic forging of the crane wheel is achieved. Compared with the prior art, automatic forging can be carried out on the wheel of the large bridge crane, the positioning and machining precision is improved, the production efficiency of the forged steel wheel can be improved, and the production cost is saved.

Description

Technical Field

[0001] The invention belongs to the field of crane wheel forging, in particular to an automatic forging turntable for a large bridge crane wheel and a processing method thereof. Background Art

[0002] As one of the key components of double-girder bridge crane operation, forged steel wheels can bear the load and weight generated by various movements of the crane. The wheels evenly disperse the load through contact with the rails and transfer it to the bridge foundation to ensure the stability and safety of the entire crane system.

[0003] At present, the degree of automation in the crane wheel forging process in my country is relatively low. The outer flange of the forged wheel body, the inner concave on both sides of the wheel, and the pre-through hole in the middle of the wheel mainly rely on workers to clamp the forging die. In addition, the forging process requires 2-3 workers to manually feed materials, flip workpieces, clamp the die, etc., which is not only unsafe but also increases labor costs.

[0004] If an automated forging process can be designed for crane wheels, manpower can be reduced, while processing safety can be increased, production efficiency can be greatly improved, and production costs can be reduced. Summary of the invention

[0005] The present invention provides a large bridge crane wheel automatic forging turntable and a processing method thereof, which can realize automatic forging of the wheels of large bridge cranes, improve the production efficiency of forged steel wheels, and save production costs. The present invention designs the automatic forging turntable to include a turntable mechanism, a step-by-step forging die, a power mechanism, and a cylinder lifting mechanism. The power mechanism drives the turntable mechanism to rotate, the step-by-step forging die is evenly arranged on the turntable mechanism, and the cylinder lifting mechanism is used to lift the crane wheel being forged, and cooperates with a mechanical arm and an air forging hammer of air forging, thereby realizing the automatic forging processing of the crane wheel.

[0006] The technical solution to realize the present invention is: an automated forging turntable for large bridge crane wheels, the automated forging turntable comprising a turntable mechanism, a step-by-step forging die, a power mechanism and a cylinder lifting mechanism, the power mechanism drives the turntable mechanism to rotate, the step-by-step forging die is evenly arranged on the turntable mechanism, the cylinder lifting mechanism is used to lift the crane wheel being forged, and cooperates with a manipulator and an air forging hammer to realize the automated forging of the crane wheel.

[0007] A processing method for an automated forging processing turntable for a large bridge crane wheel. The specific steps of the automated forging processing of the crane wheel are as follows:

[0008] S1: Upset forging at the initial position: The first station is facing the direction of the cylinder device, and the air forging hammer is located above the first station and is fixed; when a crane wheel needs to be forged, the steel is placed in the circular groove of the first station and the steel is upset by the air forging hammer; and the upset steel is clamped by the manipulator and left the first station;

[0009] S2: Processing of the second station: The servo motor drives the worm to rotate, thereby driving the rotary table needle to rotate 45 degrees, so that the second station is turned to the bottom of the air forging hammer, and then the steel to be upset is placed on the first concave mold on both sides of the wheel. The forging hammer works to process the concave on both sides of the spoke. When one side of the wheel is processed, the cylinder works to lift the second lifting piece through the first group of pistons, and then the wheel is ejected from the circular groove of the station. The wheel is clamped by the robot and turned over to continue processing the other side;

[0010] S3: Processing of the third station: After the processing of the second station is completed, the robot clamps the wheel, and after the rotary table continues to rotate 45°, the third station is moved to the bottom of the air forging hammer for processing. The third station is also used to further process the concave on both sides of the wheel spokes;

[0011] S4: Processing of the fourth to sixth stations: After the wheel is lifted up and clamped, the rotary table 3 continues to rotate 45°. The fourth station is located below the air forging hammer. The wheel is erected by the manipulator, that is, the wheel axis is horizontal to the ground, and the wheel end face is consistent with the direction of the mold, and the outer circle rim of the wheel body is processed. The fourth, fifth and sixth stations are all for processing the outer circle rim of the wheel body;

[0012] S5: Processing of the seventh station: After the wheel is clamped, the rotary table continues to rotate 45°. The seventh station is located below the forging hammer. The wheel is placed at the seventh station to process the pre-through hole in the middle of the wheel. When one side of the wheel is processed, the cylinder works to lift the first lifting piece through the second group of pistons, and then the wheel is ejected from the circular groove of the station. The wheel is clamped by the robot and turned over to continue processing the other side.

[0013] S6: Processing at the eighth station: After the seventh station is processed, the wheel is clamped, and after the rotary table continues to rotate 45°, the eighth station is processed. The eighth station is also for further processing of the middle through hole of the wheel.

[0014] Compared with the prior art, the present invention has the following significant advantages:

[0015] 1. The present invention arranges various dies required for forging wheels on one table, and replaces the dies by rotation, without the need for repeated clamping and feeding, thereby increasing work efficiency.

[0016] 2. The turntable in the present invention cooperates with the manipulator to replace the workers in the prior art who manually perform tasks such as feeding and turning over workpieces, thereby reducing costs and increasing safety.

[0017] 3. The dies in the present invention are evenly arranged, and the power structure is coordinated with the rotary table, so that the positioning accuracy and processing accuracy are higher during the forging process.

[0018] 3. The present invention can forge wheels of different models and sizes by changing the size of the mold on the rotating table, and has high versatility. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 A three-dimensional diagram of the patent of this invention;

[0020] Figure 2 It is a schematic diagram of the base of the rotating table;

[0021] Figure 3 is a schematic diagram of a rotating table;

[0022] Figure 4 The first concave molds on both sides of the wheel;

[0023] Figure 5 The second concave molds are provided on both sides of the wheel;

[0024] Figure 6 A first pre-through hole mold in the middle of the wheel;

[0025] Figure 7 A second pre-through hole mold in the middle of the wheel;

[0026] Figure 8 This is a schematic diagram of the dust cover on the surface of the rotating table;

[0027] Fig. 9 It is a schematic diagram of the power input device assembly;

[0028] Fig.10 It is the schematic diagram of the transmission worm;

[0029] Fig.11 is a schematic diagram of a servo motor;

[0030] Fig.12 It is a schematic diagram of the bearings and bearing seats at both ends of the worm;

[0031] Fig.13 It is a schematic diagram of the cylinder device assembly;

[0032] Fig.14 is a schematic diagram of the second jacking member of the wheel;

[0033] Fig.15 Schematic diagram of the first lifting piece of the wheel.

[0034] Fig.16 The working state of the bottom cylinder device when the second lifting member is lifted;

[0035] Fig.17 The working state of the bottom cylinder device when the first lifting member is lifted;

[0036] Fig.18 The position of each station at the beginning of forging;

[0037] Fig.19 This is the distribution of eight workstations.

[0038] Figure 1 Reference numerals in the figures:

[0039] 1-cylinder device; 2-base; 3-rotating table; 4-first lifting piece; 5-first pre-through hole mold; 6-second pre-through hole mold 6; 7-dust cover; 8-second lifting piece; 9-second inner concave molds 9 on both sides; 10-first inner concave molds 10 on both sides; 11-power mechanism. DETAILED DESCRIPTION

[0040] The following is combined with Figure 1-15 The present invention is further described with reference to the accompanying drawings and specific embodiments.

[0041] The present invention is an automatic forging and processing turntable for large bridge crane wheels, which can realize automatic forging of wheels of large bridge cranes. The diameter of the wheels of the large bridge cranes is usually 500mm to 1000mm, and the weight is greater than 0.2t.

[0042] like Figure 1 As shown: the specific structure of the automated forging turntable includes: an automated step-by-step forging die, a forging turntable mechanism, a power mechanism, and a cylinder lifting mechanism, so as to cooperate with the robot arm and the air forging hammer to realize the automated forging of the crane wheel.

[0043] The turntable mechanism for forging processing includes a base 2 and a rotating table 3; the rotating table 3 is installed on the base 2 and can rotate on the base 2;

[0044] like Figure 2 As shown: the connecting part between the base 2 and the rotating table 3 is a circular boss, and a small groove is processed on the side of the circular boss for adding lubricating oil or grease for lubrication; two air inlet pipes are arranged near the bottom of the base 2 to connect the two pipes of the cylinder device 1;

[0045] like Figure 3 As shown, a tapered through hole matching the boss of the base 2 is machined in the middle of the rotating table 3, so that it can be sleeved on the boss of the base 2 for rotation;

[0046] like Figure 3 As shown, the surface of the rotating table 3 is provided with 8 station slots along the circumference for installing the forging die; the station slots are evenly distributed along the circumference, and the angle between each station is 45°; the position without any die is the first station, and the second to eighth stations are respectively along the clockwise direction, as shown in FIG. Fig.19 As shown;

[0047] A circular groove is machined on the surface of the rotating table 3 for installing the dust cover 7. The dust cover 7 is set to a circular cover structure, and the bottom edge is stuck in the circular groove on the surface of the rotating table 3 to prevent iron filings and dust from falling into the lubricating oil during processing and affecting lubrication; Figure 8 shown.

[0048] The outer circle of the rotating table 3 is evenly provided with semi-cylindrical protrusions along the circumferential direction, which are used to cooperate with the threads on the cylindrical worm in the power mechanism. The cylindrical worm in the power mechanism rotates, thereby driving the rotating table 3 to rotate.

[0049] The step-by-step forging molds include three groups of molds. The first group of molds includes first concave molds 10 on both sides and second concave molds 9 on both sides, which are used to process the spoke part of the crane wheel; the second mold includes three wheel body outer cylindrical flange molds, which are used for the outer cylindrical rim of the crane wheel; the third group of molds includes a first pre-through hole mold 5 and a middle second pre-through hole mold 6, which are used to process the intermediate shaft hole of the crane wheel.

[0050] Specifically, the first concave mold 10 on both sides is installed at the second station, the second concave mold 9 on both sides is installed at the third station, the first pre-through hole mold 5 is installed at the seventh station, and the second pre-through hole mold 6 is installed at the eighth station. The fourth, fifth and sixth stations are equipped with three wheel body outer circle flange molds, and the sizes of the three molds are gradually increased, which are used to gradually realize the gradual processing of the wheel rim;

[0051] Figure 4 and Figure 5 They are respectively the first concave mold 10 on both sides and the second concave mold 9 on both sides; the two concave molds have similar structures, both are circular rings, with a flat bottom placed in the work station slot, a trapezoidal cross-section, and curved sides; the second concave molds 9 on both sides are larger in size than the first concave molds 10 on both sides, and are used for the gradual processing of the spoke part, thereby reducing the stress during the processing.

[0052] Figure 6 and Figure 7 They are respectively the first middle pre-through hole mold 5 and the second middle pre-through hole mold 6; the two pre-through hole molds have similar structures, both of which are smooth cones on the top; the second pre-through hole mold 6 is larger than the first pre-through hole mold 5 and is used for the gradual processing of the spoke part, thereby reducing the stress during the processing.

[0053] The cylinder lifting mechanism comprises a cylinder device 1, a first lifting member 4, a second lifting member 8 and two sets of piston devices; Fig.14 As shown, the second lifting member 8 is in the shape of a cone; Fig.15 As shown, the first lifting member 4 is a sleeve-shaped structure composed of two arcs and has a taper.

[0054] Specifically, the circular bottom of the second and third stations on the rotating table 3 is provided with a frustum-shaped through hole, and the second lifting member 8 is placed in the frustum-shaped through hole of the circular bottom of the second and third stations; and the small diameter section of the frustum is at the bottom, and the large diameter section is at the top (downward along the direction of gravity), which is used to limit the downward movement (toward the direction of gravity) of the lifting member when cooperating with the through hole structure on the station.

[0055] The circular bottom of the seventh and eighth stations on the rotating table 3 is provided with a through hole for installing the first lifting member 4, and the first lifting member 4 is installed in the through hole of the first lifting member 4 in the circular bottom of the seventh and eighth stations on the rotating table 3; the first lifting member 4 is also a sleeve-like structure composed of two circular arcs, with the small diameter section at the bottom and the large diameter section at the top (downward along the direction of gravity), which is used to limit the downward movement (toward the direction of gravity) of the lifting member when cooperating with the through hole structure on the station.

[0056] like Fig.13 The figure shows a cylinder device 1, which is connected to the air inlet pipe at the bottom of the base 2. When working, gas is generated through the cylinder body, and then the gas is passed into the piston through the input pipe to lift the part. When the work is finished, the valve opens, the gas leaks out through the exhaust port, the piston stops working, and the part returns to its original position.

[0057] like Fig.16 , Fig.17 As shown, two groups of piston devices are arranged in the direction where the base 2 is connected to the cylinder device 1, namely the first group of pistons and the second group of pistons, wherein the middle piston with a larger diameter is the first group of pistons, which is used to lift the second lifting member 8; the four pistons with smaller diameters are the second group of pistons, which are used to lift the first lifting member 4; the two groups of pistons are respectively connected to the two input pipes of the cylinder device 1 inside the base 2, and the two input pipes respectively control the movement of the two groups of pistons.

[0058] The second lifting piece 8 corresponds to the first group of pistons, that is, when the second and third stations are processed, the cylinder works to lift the second lifting piece 8 through the first group of pistons, and then the wheel is pushed out of the circular groove of the station, so as to proceed to the next process;

[0059] Furthermore, the first lifting member 4 corresponds to the second group of pistons, that is, when the seventh and eighth stations are processed, the cylinder works to lift the first lifting member 4 through the second group of pistons, thereby ejecting the wheel from the circular groove of the station, so as to proceed to the next process;

[0060] like Fig. 9 As shown, the power mechanism 11 includes a mounting base, a cylindrical worm, a rolling bearing and a servo motor, wherein the mounting base is fixed to the ground, rolling bearings are installed at both ends of the cylindrical worm and fixed to the mounting base through bearing seats; wherein one end of the cylindrical worm is externally connected to a servo motor, and the worm is driven to rotate by the motor.

[0061] The worm is matched with the semi-cylindrical protrusion on the circumferential direction of the rotating table 3, and the worm is driven to rotate by the motor, thereby driving the rotating table 3 to rotate on the base 2. Through servo motor control and precise calculation, the number of revolutions of the worm can determine the rotation angle of the rotating table 3. For every 4 revolutions of the worm, the rotating table 3 rotates 45°, and each process is set to 4 revolutions, thereby achieving precise control of the processing position.

[0062] The present invention discloses a large-scale bridge crane wheel automatic forging turntable, and the automatic forging method for the crane wheel is as follows:

[0063] S1: Upset forging at the initial position: The first station is facing the direction of the cylinder device, such as Fig.18 As shown; the air forging hammer is located above the first station and is fixed. When a crane wheel needs to be forged, the steel is placed in the circular groove of the first station. After the steel is initially upset to the required diameter by the air forging hammer, the manipulator clamps the upset steel away from the circular groove (the first station). At this time, the steel has no contact with the rotating table 3.

[0064] S2: Processing of the second station: The servo motor drives the worm to rotate, thereby driving the rotating table 3 to rotate 45° counterclockwise, and then the second station is transferred to the bottom of the air forging hammer, and then the steel to be upset is placed on the first concave mold 10 on both sides of the wheel. The forging hammer works to initially process the concave on both sides of the spoke. When one side of the wheel is processed, the cylinder works to lift the second lifting piece 8 through the first group of pistons, and then the wheel is ejected from the circular groove of the station. The wheel is clamped and turned over by the robot to continue processing the other side;

[0065] S3: Processing at the third station: After the processing at the second station is completed, the wheel is clamped, and after the rotary table 3 continues to rotate counterclockwise by 45°, the processing at the third station is carried out. The third station is also used to process the concave on both sides of the wheel spokes, but its mold size is larger than that of the mold size at the second station. After two processings with gradually increasing sizes, the concave on both sides of the wheel basically meets the size requirements;

[0066] S4: Processing of the fourth to sixth stations: After the wheel is lifted up and clamped, the rotary table 3 continues to rotate counterclockwise by 45°. The fourth station is located below the forging hammer. The wheel is erected by the manipulator, that is, the wheel axis is horizontal to the ground, and the wheel end face is consistent with the direction of the mold, and the outer circle rim of the wheel body is processed. The fourth, fifth and sixth stations are all for processing the outer circle rim of the wheel body. Similarly, in order to avoid excessive stress and heat, the sizes of the three molds are gradually increased. After the sixth station is processed, the outer circle rim of the wheel body is basically processed;

[0067] S5: Processing of the seventh station: After the wheel is clamped, the rotary table 3 continues to rotate counterclockwise by 45°. The seventh station is located below the forging hammer. The wheel is placed at the seventh station to process the pre-through hole in the middle of the wheel (i.e., the middle shaft hole). When one side of the wheel is processed, the cylinder works to lift the first lifting piece 4 through the second group of pistons, thereby ejecting the wheel from the circular groove of the station. The wheel is clamped by the manipulator and turned over to continue processing the other side.

[0068] S6: Processing at the eighth station: After the processing at the seventh station is completed, the wheel is clamped, and after the rotary table 3 continues to rotate counterclockwise by 45°, the processing at the eighth station is performed. The eighth station is also used to process the middle through hole of the wheel (i.e., the middle shaft hole), but its mold size is larger than that of the mold size of the seventh station. After two processings with gradually increasing sizes, the processing of the middle through hole of the wheel is basically completed;

[0069] The basic shape and size of the wheel are initially processed and can be processed later.

[0070] The above shows and describes the basic principle, main features and advantages of this invention. This invention is not limited to the above embodiments. The above embodiments and descriptions are only for explaining the principle of this invention. Without departing from the spirit and scope of this invention, this invention may have various changes and improvements, which fall within the scope of this invention to be protected. The scope of protection of this invention is defined by the attached claims and their equivalents.

Claims

1. A large bridge crane wheel automated forging turntable, characterized in that: The automated forging turntable includes a turntable mechanism, a step-by-step forging die, a power mechanism and a cylinder lifting mechanism. The power mechanism drives the turntable mechanism to rotate. The step-by-step forging die is evenly arranged on the turntable mechanism. The cylinder lifting mechanism is used to lift the crane wheel being forged, and cooperates with a manipulator and a forging hammer of an air forging to realize the automated forging of the crane wheel.

2. The large bridge crane wheel automated forging turntable according to claim 1 is characterized in that: The turntable mechanism comprises a base and a rotating table; the rotating table is rotatably connected to the base.

3. The large bridge crane wheel automated forging turntable according to claim 2 is characterized in that: A circular boss is arranged on the base for connecting with the rotating table; a tapered through hole is machined in the middle of the rotating table to match with the boss of the base; a groove is machined on the side of the circular boss on the base for adding lubricating oil or grease for lubrication; two air inlet pipes are arranged at the bottom of the base for connecting with the cylinder device in the cylinder lifting mechanism; semi-cylindrical protrusions are evenly arranged along the circumferential direction of the outer circle of the rotating table for matching with the power mechanism to realize the rotation of the rotating table under the drive of the power mechanism.

4. According to the large bridge crane wheel automated forging turntable according to claim 2, it is characterized in that: There are eight workstation slots along the circumference of the rotating table surface for installing forging dies; the workstation slots are evenly distributed along the circumference, and the angle between each workstation is 45°.

5. According to the large bridge crane wheel automated forging turntable according to claim 4, it is characterized in that: The step-by-step forging molds include three groups of molds. The first group of molds includes first concave molds on both sides and second concave molds on both sides, which are used to process the spoke part of the crane wheel; the second mold includes three wheel body outer circle flange molds, which are used for the outer circle rim of the crane wheel; the third group of molds includes a first pre-through hole mold and a middle second pre-through hole mold, which are used to process the intermediate shaft hole of the crane wheel.

6. According to the large bridge crane wheel automated forging turntable according to claim 5, it is characterized in that: The position without any mold is the first workstation, which is used to perform preliminary upsetting on the steel through an air forging hammer; the first concave molds on both sides are installed at the second workstation, the second concave molds on both sides are installed at the third workstation, the first pre-through hole mold is installed at the seventh workstation, and the second pre-through hole mold is installed at the eighth workstation; the fourth, fifth and sixth workstations are equipped with three wheel body outer circle flange molds for gradually realizing the gradual processing of the wheel rim.

7. The large bridge crane wheel automated forging turntable according to claim 6 is characterized in that: The cylinder lifting mechanism comprises a cylinder device, a first lifting piece, a second lifting piece and two groups of piston devices; the cylinder device is connected to the air inlet pipe at the bottom of the base 2; two groups of piston devices are installed on the base and connected to the input pipe of the cylinder device; the second lifting piece is installed in the frustum-shaped through hole at the circular bottom of the second and third stations, and the first lifting piece is installed in the through hole at the circular bottom of the seventh and eighth stations on the rotating table; the two groups of piston devices include a first group of piston devices and a second group of piston devices; the first group of pistons is used to lift the second lifting piece, and the second group of pistons is used to lift the first lifting piece.

8. The large bridge crane wheel automated forging turntable according to claim 7 is characterized in that: The gravity direction is downward, and the first lifting member and the second lifting member are both provided with a large diameter section at the top and a small diameter section at the bottom, and a certain taper is provided to limit the downward movement of the lifting members.

9. The large bridge crane wheel automated forging turntable according to claim 3 is characterized in that: The power mechanism includes a mounting base, a cylindrical worm gear, and a servo motor; the mounting base is fixed to the ground, the cylindrical worm gear is rotatably connected to the mounting base, the thread of the cylindrical worm gear cooperates with the semi-cylindrical protrusion on the rotating table, and the servo motor drives the cylindrical worm gear to rotate, thereby driving the rotating table to rotate.

10. The processing method of the large bridge crane wheel automated forging turntable according to claims 1-9, characterized in that: The specific steps of automated forging processing of crane wheels are as follows: S1: Upset forging at the initial position: The first station is facing the direction of the cylinder device, and the air forging hammer is located above the first station and is fixed; when a crane wheel needs to be forged, the steel is placed in the circular groove of the first station and the steel is upset by the air forging hammer; and the upset steel is clamped by the manipulator and left the first station; S2: Processing of the second station: The servo motor drives the worm to rotate, thereby driving the rotary table needle to rotate 45 degrees, so that the second station is turned to the bottom of the air forging hammer, and then the steel to be upset is placed on the first concave mold on both sides of the wheel. The forging hammer works to process the concave on both sides of the spoke. When one side of the wheel is processed, the cylinder works to lift the second lifting piece through the first group of pistons, and then the wheel is ejected from the circular groove of the station. The wheel is clamped by the robot and turned over to continue processing the other side; S3: Processing of the third station: After the processing of the second station is completed, the robot clamps the wheel, and after the rotary table continues to rotate 45°, the third station is moved to the bottom of the air forging hammer for processing. The third station is also used to further process the concave on both sides of the wheel spokes; S4: Processing of the fourth to sixth stations: After the wheel is lifted up and clamped, the rotary table 3 continues to rotate 45°. The fourth station is located below the air forging hammer. The wheel is erected by the manipulator, that is, the wheel axis is horizontal to the ground, and the wheel end face is consistent with the direction of the mold, and the outer circle rim of the wheel body is processed. The fourth, fifth and sixth stations are all for processing the outer circle rim of the wheel body; S5: Processing of the seventh station: After the wheel is clamped, the rotary table continues to rotate 45°. The seventh station is located below the forging hammer. The wheel is placed at the seventh station to process the pre-through hole in the middle of the wheel. When one side of the wheel is processed, the cylinder works to lift the first lifting piece through the second group of pistons, and then the wheel is ejected from the circular groove of the station. The wheel is clamped by the robot and turned over to continue processing the other side. S6: Processing at the eighth station: After the seventh station is processed, the wheel is clamped, and after the rotary table continues to rotate 45°, the eighth station is processed. The eighth station is also for further processing of the middle through hole of the wheel.

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