Automatic stamping production system and production method

Abstract

The invention belongs to the field of stamping, and particularly relates to an automatic stamping production system and method. The press machine in the first drawing process adopts an intermittent stamping mode, and the press machine in the subsequent process adopts a continuous stamping mode; and a robot matched with the press machine is arranged on the front sides of the press machine in the first drawing process and the press machine in the subsequent process. Compared with the prior art, the method has the beneficial effects that the efficiency is high; the energy consumption is low; the noise is low; the cost is low; and other benefits are obtained.

Description

Technical Field

[0001] The invention belongs to the field of stamping, and in particular relates to a stamping automated production system and a production method. Background Art

[0002] The traditional stamping automated production line adopts an intermittent production mode, that is, during the stamping production process, the press slide stops at the top dead center. After the robot and other automated equipment move the materials, the press brake is disengaged, the clutch is engaged, and the slide proceeds to the next working cycle. However, this working mode has low efficiency and high energy consumption. About 10 years ago, a continuous production mode appeared, that is, during the stamping production process, the press slide does not stop at the top dead center, but runs continuously to proceed to the next working cycle. The trajectory movement of robots and other automated handling equipment and the trajectory movement of the press slide are coordinated to achieve continuous material handling. This production line has the advantages of high efficiency, slightly lower energy consumption, and better working conditions of molds and equipment, and has gradually replaced the traditional intermittent mode production line.

[0003] However, the continuous production mode has high requirements on the configuration of the press, especially the first drawing process press, which has a slide stroke of 1400mm and a main motor of more than 500Kw. Therefore, the cost is high and it is not conducive to promotion. Summary of the invention

[0004] The present invention provides a stamping automated production system and production method, which can effectively solve the problems raised in the above background technology.

[0005] To achieve the above object, the present invention provides the following technical solutions: A stamping automated production system, comprising a stamping production line and a control system, wherein the stamping production line comprises an R11 robot for depalletizing, a cleaning machine is arranged at the next station of the R11 robot, an R12 robot is arranged at the next station of the cleaning machine, a No. 1 press of a first-order drawing process is arranged at the next station of the R12 robot, a subsequent process press is arranged at the subsequent station of the No. 1 press, and subsequent process robots are arranged at the front and rear sides of the subsequent process press; The control system includes: a synchronous controller for controlling the press and a robot controller for controlling the robot; The control cabinet for controlling the 1# press is connected to the synchronous controller via a bus, and the control cabinet for controlling the 1# press communicates with the control cabinet for controlling the presses of the subsequent processes; the drive cabinet for driving the motor of the 1# press and the drive cabinet for driving the motor of the presses of the subsequent processes are connected to the synchronous controller via a bus; The control cabinet of the 1# press and the control cabinet of the subsequent process presses are connected to the robot controller through the bus. The robot drivers used to control the R11 robot and the R12 robot are connected to the robot controller through the bus, and the robot drivers used to control each subsequent process are connected to the robot controller.

[0006] A stamping automation production method using a stamping automation production system, the steps comprising: using a press control method on a press so that the press in a first-sequence drawing process adopts an intermittent stamping mode and the press in a subsequent process adopts a continuous stamping mode; using a robot control method on a robot so that the robot cooperates with the intermittent stamping mode of the press in the first-sequence drawing process and the continuous stamping mode of the press in the subsequent process.

[0007] Preferably, the press control method comprises the following steps: (1) The synchronous controller receives signals from each control cabinet and each drive cabinet, wherein the control cabinet signal includes a press angle encoder signal and a synchronous phase deviation angle signal, and the drive cabinet signal includes feedback signals from a drive device and a motor. The synchronous controller sends control instructions to each drive cabinet according to the press angle encoder signal and the synchronous phase deviation angle signal of the control cabinet after calculation and processing; (2) After starting the synchronous controller, the presses in each subsequent process are automatically started in sequence according to the pre-set phase angle. If the phase difference is greater than the set range, the engine of the press sends a fault signal and stops. The drive cabinet adjusts the motor speed of the press in real time according to the synchronous deviation angle signal calculated in step (1) to achieve a synchronous deviation angle within the set range, thereby ensuring the synchronous control effect of all presses; (3) Set the 1# press to be controlled in the form of a virtual axis. When the 1# press is started, the virtual axis will synchronously follow the spindle of the subsequent process press. When the angle of the virtual axis of the 1# press reaches the set value of the R12 robot teach pendant, the R12 robot will synchronously enter and exit the press following the virtual axis angle, and simultaneously start the 1# press's own spindle to realize the intermittent stamping mode of the first press. Design an angle comparison between the press's own spindle and the virtual axis in the system to prevent angle interference.

[0008] Preferably, the robot control method comprises the following steps: (1) The robots in each subsequent process enter and exit the press synchronously in real time, and the robot speed is adjusted by the robot controller so that it follows the movement of the press; (2) During synchronous control, the robot controller reads the current cam angle and stroke number of the subsequent process press in real time through the control cabinet. The robot controller calculates and adjusts the speed by comparing the position of each subsequent process robot with the cam angle value of the press, and sends a control signal to each subsequent process robot to achieve real-time synchronization of the angle of each subsequent process robot with that of each subsequent process press; (3) Set the 1# press to be controlled in the form of a virtual axis. When the 1# press is started, the virtual axis will synchronously follow the spindle of the subsequent process press. When the virtual axis angle of the 1# press reaches the set value of the R12 robot teach pendant, the R12 robot will synchronously enter and exit the press following the virtual axis angle.

[0009] Compared with the prior art, the present invention has the following beneficial effects: (1) High efficiency. A total of 13 groups of internal parts using this technology have an average cycle time of 10.7 SPM. There are 6 sets of parts that have reached the highest design cycle time of 12 SPM for the entire line, accounting for 46%. Among them, the average cycle time of one production line is 11.3 SPM, and the GSPH can reach 550. Compared with the existing production lines of the same type in the industry, the average production cycle of a single model is far higher than the level; in addition, based on the improvement of the cycle time, the annual production capacity of the stamping workshop has been greatly improved.

[0010] (2) Low energy consumption. In intermittent mode, the press slide stroke is used 18 times, and in continuous mode, the slide stroke is ≤12 times, and the press slide speed is reduced. At the same time, in continuous mode production, the clutch brake does not need to be frequently operated, reducing the rapid acceleration and deceleration process of the main motor, and the energy consumption of the production line can be reduced by 5%.

[0011] (3) Low noise. The continuous mode is used for production, and the number of strokes of the press slide is small. The impact on the mold during the stamping process is reduced. According to on-site measurements, the average noise in the workshop is reduced by 6%, which greatly reduces the incidence of occupational diseases among employees.

[0012] (4) Low cost. Production efficiency is improved, and the daily plan is completed on time or ahead of schedule, reducing overtime costs and energy costs. In addition, the maintenance cycle of the press clutch and brake is extended, reducing maintenance costs by 50,000 yuan / year.

[0013] (5) Other benefits. In continuous mode production, the mold is less impacted, and the service life of bolts and other structural parts is extended. The vibration of the press is small, and the equipment failure rate such as loose bolts and abnormal connection parts is reduced. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] The accompanying drawings are used to provide a further understanding of the present invention and constitute a part of the specification. Together with the embodiments of the present invention, they are used to explain the present invention and do not constitute a limitation of the present invention. In the accompanying drawings: Figure 1It is a structural schematic diagram of the stamping production line of the present invention; Figure 2 It is a schematic diagram of the control structure of the present invention; Figure 3 A robot trajectory diagram of the present invention; Figure 4 This is an example diagram of setting key trajectory point parameters of the robot of the present invention; Figure 5 This is an example diagram of setting the robot synchronous following parameters of the present invention. DETAILED DESCRIPTION

[0015] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0016] A stamping automated production system, comprising a stamping production line and a control system, wherein the stamping production line comprises an R11 robot for depalletizing, a cleaning machine is arranged at the next station of the R11 robot, an R12 robot is arranged at the next station of the cleaning machine, a No. 1 press of a first-order drawing process is arranged at the next station of the R12 robot, a subsequent process press is arranged at the subsequent station of the No. 1 press, and subsequent process robots are arranged at the front and rear sides of the subsequent process press; The control system includes: a synchronous controller for controlling the press and a robot controller for controlling the robot; The control cabinet for controlling the 1# press is connected to the synchronous controller via a bus, and the control cabinet for controlling the 1# press communicates with the control cabinet for controlling the presses of the subsequent processes; the drive cabinet for driving the motor of the 1# press and the drive cabinet for driving the motor of the presses of the subsequent processes are connected to the synchronous controller via a bus; The control cabinet of the 1# press and the control cabinet of the subsequent process presses are connected to the robot controller through the bus. The robot drivers used to control the R11 robot and the R12 robot are connected to the robot controller through the bus, and the robot drivers used to control each subsequent process are connected to the robot controller.

[0017] A stamping automation production method, the steps comprising: using a press control method on a press so that the press in the first drawing process adopts an intermittent stamping mode and the press in the subsequent process adopts a continuous stamping mode; using a robot control method on a robot so that the robot cooperates with the intermittent stamping mode of the press in the first drawing process and the continuous stamping mode of the press in the subsequent process.

[0018] The press control method comprises the following steps: (1) The synchronous controller receives signals from each control cabinet and each drive cabinet, wherein the control cabinet signal includes a press angle encoder signal and a synchronous phase deviation angle signal, and the drive cabinet signal includes feedback signals from a drive device and a motor. The synchronous controller sends control instructions to each drive cabinet according to the press angle encoder signal and the synchronous phase deviation angle signal of the control cabinet after calculation and processing; (2) After starting the synchronous controller, the presses in each subsequent process will automatically start in sequence according to the pre-set phase angle. If the phase difference is greater than the set range, the engine of the press will send a fault signal and shut down. The drive cabinet will adjust the motor speed of the press in real time according to the synchronous deviation angle signal calculated in step (1) to achieve a synchronous deviation angle within the set range, thereby ensuring the synchronous control effect of all presses; the synchronous angle of the entire line press is ±3°.

[0019] (3) Set the 1# press to be controlled in the form of a virtual axis. When the 1# press is started, the virtual axis will synchronously follow the spindle of the subsequent process press. When the angle of the virtual axis of the 1# press reaches the set value of the R12 robot teach pendant, the R12 robot will synchronously enter and exit the press following the virtual axis angle, and simultaneously start the 1# press's own spindle to realize the intermittent stamping mode of the first press. Design an angle comparison between the press's own spindle and the virtual axis in the system to prevent angle interference.

[0020] The robot control method comprises the following steps: (1) The robots in each subsequent process enter and exit the press synchronously in real time, and the robot speed is adjusted by the robot controller so that it follows the movement of the press; (2) During synchronous control, the robot controller reads the current cam angle and stroke count of the press in the subsequent process in real time through the control cabinet. The robot controller calculates and adjusts the speed by comparing the position of each subsequent process robot with the cam angle value of the press, and sends a control signal to each subsequent process robot to achieve real-time synchronization of the angle of each subsequent process robot with that of the press.

[0021] (3) Set the 1# press to be controlled in the form of a virtual axis. When the 1# press is started, the virtual axis will synchronously follow the spindle of the subsequent process press. When the virtual axis angle of the 1# press reaches the set value of the R12 robot teach pendant, the R12 robot will synchronously enter and exit the press following the virtual axis angle.

[0022] like Figure 3As shown in the figure, the corresponding press angle is set at the key trajectory points (WU point / BP point / WL point / BD point) of the subsequent process robot. When the subsequent process robot is started, the synchronization point (WSP point) is coupled with the angle of the front press during unloading, and the speed is adjusted according to the angles set by the WU point and the BP point, so as to move synchronously with the front press. Similarly, when loading the machine, the angle of the background robot is coupled at the synchronization point (WSR point), and according to the angles set by the WL point and the BD point, it runs synchronously with the background press and enters the background press to load the material.

[0023] In the robot control method, the feeding permission signal sent by the robot controller to the robot depends on the following angle between the robot and the press. During operation, a safe distance is maintained according to the robot synchronization following parameters, and the robot safety distance, monitoring function and minimum allowable safety distance are set in the upper control system of the automated control. Once it is detected that the safety distance is too low and there is a risk, the robot can be stopped quickly.

[0024] In the robot control method, the robot controller scans and reads the position of the Y-axis of the subsequent process robot in real time, and determines the process direction of the subsequent process robot exiting the press according to the real-time change value of the Y-axis position of the subsequent process robot and the safety position signal of the subsequent process robot. When the subsequent process robot is in the process of exiting the press, an abnormal shutdown signal such as an emergency stop or safety protection appears, and the subsequent process robot escapes from the safety area of ​​the press and then stops urgently.

[0025] like Figure 3 As shown in the figure, when the subsequent process robot is in the process of exiting the press (the process of the unloading robot running from the AP point to the OU point, the loading robot running from the AD point to the OL point), if there are emergency stop, safety protection abnormality and other abnormal stop signals, the subsequent process robot will escape from the press safety area and then make an emergency stop. This avoids the risk of stopping during the process of loading and exiting the press and colliding with the press, and the risk of collision caused by insufficient braking distance for loading when the unloading robot stops during the process of exiting the press.

[0026] In the control method of the press, the press cam angle is used to determine whether the press of the subsequent process is in the return process, the stop logic of the press of the subsequent process is simplified, and the type of shutdown due to equipment failure is distinguished. During the return process of the press of the subsequent process, except for the emergency stop button being triggered, if any fault or stop command occurs, the press slider does not stop running, and continues to return to the top dead center before stopping.

[0027] Finally, it should be noted that the above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art can still modify the technical solutions described in the aforementioned embodiments or replace some of the technical features therein by equivalents. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. A stamping automation production system, comprising a stamping production line and a control system, wherein the stamping production line comprises an R11 robot for depalletizing, a cleaning machine is arranged at the next station of the R11 robot, an R12 robot is arranged at the next station of the cleaning machine, a 1# press of a first-order drawing process is arranged at the next station of the R12 robot, a subsequent process press is arranged at the subsequent station of the 1# press, and subsequent process robots are arranged at the front and rear sides of the subsequent process press; The control system comprises: a synchronous controller for controlling the press and a robot controller for controlling the robot; The control cabinet for controlling the 1# press is connected to the synchronous controller via a bus, and the control cabinet for controlling the 1# press communicates with the control cabinet for controlling the presses of the subsequent processes; the drive cabinet for driving the motor of the 1# press and the drive cabinet for driving the motor of the presses of the subsequent processes are connected to the synchronous controller via a bus; The control cabinet of the 1# press and the control cabinet of the subsequent process presses are connected to the robot controller through the bus. The robot drivers used to control the R11 robot and the R12 robot are connected to the robot controller through the bus, and the robot drivers used to control each subsequent process are connected to the robot controller.

2. A stamping automation production method using the stamping automation production system of claim 1, characterized in that the steps include: A press control method is adopted for the press, so that the press in the first drawing process adopts the intermittent stamping mode, and the press in the subsequent process adopts the continuous stamping mode; a robot control method is adopted for the robot, so that the robot cooperates with the intermittent stamping mode of the press in the first drawing process and the continuous stamping mode of the press in the subsequent process.

3. The stamping automation production method according to claim 2, characterized in that: The press machine control method comprises the following steps: (1) The synchronous controller receives signals from each control cabinet and each drive cabinet, wherein the control cabinet signal includes a press angle encoder signal and a synchronous phase deviation angle signal, and the drive cabinet signal includes feedback signals from a drive device and a motor. The synchronous controller sends control instructions to each drive cabinet according to the press angle encoder signal and the synchronous phase deviation angle signal of the control cabinet after calculation and processing; (2) After starting the synchronous controller, the presses in each subsequent process are automatically started in sequence according to the pre-set phase angle. If the phase difference is greater than the set range, the engine of the press sends a fault signal and stops. The drive cabinet adjusts the motor speed of the press in real time according to the synchronous deviation angle signal calculated in step (1) to achieve a synchronous deviation angle within the set range, thereby ensuring the synchronous control effect of all presses; (3) Set the 1# press to be controlled in the form of a virtual axis. When the 1# press is started, the virtual axis will synchronously follow the spindle of the subsequent process press. When the angle of the virtual axis of the 1# press reaches the set value of the R12 robot teach pendant, the R12 robot will synchronously enter and exit the press following the virtual axis angle, and simultaneously start the 1# press's own spindle to realize the intermittent stamping mode of the first press. Design an angle comparison between the press's own spindle and the virtual axis in the system to prevent angle interference.

4. The stamping automation production method according to claim 2, characterized in that: The robot control method comprises the following steps: (1) The robots in each subsequent process enter and exit the press synchronously in real time, and the robot speed is adjusted by the robot controller so that it follows the movement of the press; (2) During synchronous control, the robot controller reads the current cam angle and stroke number of the subsequent process press in real time through the control cabinet. The robot controller calculates and adjusts the speed by comparing the position of each subsequent process robot with the cam angle value of the press, and sends a control signal to each subsequent process robot to achieve real-time synchronization of the angle of each subsequent process robot with that of each subsequent process press; (3) Set the 1# press to be controlled in the form of a virtual axis. When the 1# press is started, the virtual axis will synchronously follow the spindle of the subsequent process press. When the virtual axis angle of the 1# press reaches the set value of the R12 robot teach pendant, the R12 robot will synchronously enter and exit the press following the virtual axis angle.

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