Online monitoring system for piston ring doctor blade processing quality

Abstract

The invention relates to the technical field of piston ring processing, and discloses an online monitoring system for piston ring doctor blade processing quality, which comprises a detection unit, a transmission unit, an integrated analysis unit and the like. According to the device, the outline data of outer circle winding of the doctor blade can be monitored on line, so that real-time roundness value data and waviness value data can be obtained through calculation, it is guaranteed that products completely meet the technical requirements, and unqualified products are completely eradicated. Meanwhile, through online monitoring, quality problems can be found and processed in time, batch quality problems are avoided, and losses and influences are reduced. A mapping relation between product quality and equipment, processing personnel or other related factors is established, the influence of manual control of mold precision, assembly precision and service life on roundness and waviness can be verified, and a direction is indicated for a subsequent quality improvement strategy. And the product batch information is obtained and recorded during processing, so that process tracing can be conveniently carried out when needed.

Description

Technical Field

[0001] The invention relates to the technical field of piston ring processing, and in particular to an online monitoring system for the processing quality of piston ring scrapers. Background Art

[0002] The three-combination oil ring in the automobile engine is a piston ring composed of three oil scraping steel plates and two elastic lining rings. The main function of the three-combination oil ring is to scrape off the excess oil on the cylinder wall and form a uniform oil film on the cylinder wall, which can prevent the oil from entering the combustion chamber, while reducing the wear between the piston, piston ring and cylinder wall and reducing friction resistance.

[0003] The scraper blade is the most important component of the three-piece oil ring. The quality of its production directly affects the quality of the oil ring product. In the scraper blade production process, roundness and waviness are important indicators to measure the scraper blade quality, and are also important parameters for controlling engine fuel consumption. In the prior art, the method for detecting the roundness and waviness of the scraper blade is: place the formed scraper blade workpiece in a standard compass of nominal diameter, and clamp the upper and lower ends with pressure plates; use a contact probe to detect the outer contour shape of the scraper blade (under the detection magnification × 1000). The detection results are as follows: Figure 1 As shown. The outermost circle in the figure is the arc where the outermost point of the actual contour of the scraper is located (i.e. the position of the maximum diameter of the actual contour); the innermost circle is the arc where the innermost point of the actual contour of the scraper is located (i.e. the position of the minimum diameter of the actual contour); the actual contour diagram of the scraper is between the two. The distance between the maximum diameter position and the minimum diameter position of the actual contour is the roundness parameter of the scraper; the height and low difference of the waveform within the 30° sector contour range selected with the contour circle center as the center is the waviness.

[0004] The existing quality control method for scraper processing products is: the production quality is controlled by manual adjustment of the mold's own precision, assembly precision, and mold life during the production process. After the scraper is wound and produced, the roundness and waviness are sampled and tested, with a sampling rate of 0.02%. This product quality control method relies more on the operator's debugging and control capabilities, and cannot guarantee the fluctuation of waviness during product processing. At the same time, the sampling method cannot guarantee the qualified rate of the product, and cannot prevent the flow of unqualified products to the client. In addition, quality problems cannot be discovered in time during the product production process, which is prone to batch quality problems. Summary of the invention

[0005] SUMMARY OF THE INVENTION

[0006] The technical problem solved by the present invention is that the existing scraper processing product quality control method cannot meet the quality control requirements.

[0007] The purpose of the present invention can be achieved through the following technical solutions:

[0008] An online monitoring system for the processing quality of a piston ring scraper comprises:

[0009] A detection unit, which is arranged on the scraper blade winding processing equipment and is used to detect and obtain the outer circle contour runout data of the formed part of the scraper blade workpiece being processed in real time;

[0010] The integrated analysis unit and the detection unit form a data transmission channel through the transmission unit, and obtain the outer circle contour runout data of the formed part of the scraper workpiece being processed through the transmission channel; and are used to analyze the received outer circle contour runout data to obtain the real-time waviness and roundness data of the product, and its working process is as follows:

[0011] After the product starts to be processed, the diameter data of the scraper product being processed and the processing speed data of the equipment on which it is located are obtained, and the circumference processing time of the product is determined according to the diameter of the processed product and the processing speed of the equipment;

[0012] Get roundness value data:

[0013] When the product is processed for less than one week, the outer contour runout data of the product within the range of the product forming starting end is obtained from the instant detection point to the direction of the detected point, and the max value and min value are taken out and subtracted to obtain the roundness value;

[0014] When the product is processed for a full circle, the outer circle contour runout data is obtained from the instant detection point in the direction of the detected point within a circle, the maximum value and the minimum value are obtained, and the roundness value is obtained by subtracting them;

[0015] Get the waviness value data:

[0016] Starting from the instant detection point, take the product outer circle contour runout data within a range of 30° in the direction of the detected point, take out the maximum value and the minimum value, and subtract them to obtain the waviness value;

[0017] After obtaining the roundness value and the waviness value, they are compared with the preset roundness threshold and the waviness threshold respectively. If they exceed the threshold, an alarm message is issued.

[0018] In one embodiment of the present invention, the detection unit is a contact or non-contact sensor.

[0019] In one embodiment of the present invention, the detection point of the detection unit is located at one end of the formed portion of the scraper product close to the unformed portion.

[0020] In one aspect of the present invention: it also includes a database for storing outer circle contour runout data.

[0021] In one embodiment of the present invention, a display unit is also included for displaying the outer circle contour runout data obtained by detection and the roundness value data and waviness value data calculated by the integrated analysis unit.

[0022] In one embodiment of the present invention, the roundness threshold is 20μ, and the waviness threshold is 3μ / 30°.

[0023] In one embodiment of the present invention: the roundness threshold includes a first threshold and a second threshold, the first threshold is smaller than the second threshold, when the real-time roundness value exceeds the first threshold, an alarm message is issued, and when the real-time roundness value exceeds the second threshold, an alarm message is issued and the equipment is shut down.

[0024] In one embodiment of the present invention, a roundness value and a waviness value variation curve are generated after the product processing is completed.

[0025] In one solution of the present invention, while the product is being processed, the equipment model, raw material batch number, product batch number, processing personnel data information are obtained and stored in a database together with the roundness value and waviness value change curve.

[0026] An online monitoring system for the processing quality of a piston ring scraper according to the present invention has at least one of the following technical effects:

[0027] This application can calculate the real-time roundness value data and waviness value data by online monitoring of the contour data of the outer circle of the scraper, ensuring that the product meets the technical requirements 100% and preventing the outflow of unqualified products. At the same time, through online monitoring, quality problems can be discovered and handled more promptly when they occur, avoiding batch quality problems and reducing losses and impacts. By establishing a mapping relationship between product quality and equipment, processing personnel or other related factors, it is possible to verify the impact of mold accuracy, assembly accuracy, and life human control on roundness and waviness, and point out the direction for subsequent quality improvement strategies. Acquire and record product batch information while processing to facilitate process traceability when necessary.

[0028] Additional aspects and advantages of the present invention will be given in part in the following description and in part will be obvious from the following description, or will be learned through practice of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] The above and / or additional aspects and advantages of the present invention will become apparent and easy to understand from the description of the embodiments in conjunction with the following drawings. Obviously, the drawings in the following description are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative work. Among them:

[0030] Figure 1 It is a schematic diagram of the concept of roundness and waviness of the present invention;

[0031] Figure 2 It is a structural schematic diagram of the scraper blade winding process of the present invention;

[0032] Figure 3 It is a schematic diagram of the system composition of the present invention;

[0033] Figure 4 It is a structural schematic diagram of an embodiment of the present invention;

[0034] Figure 5 It is a data variation diagram of the outer circle profile of the scraper blade of the present invention.

[0035] The reference numerals in the figure are: 1. crimping roller; 2. bending roller; 3. center roller; 4. stretching rod; 5. detection unit; 6. integrated analysis unit; 7. database; 8. display unit. DETAILED DESCRIPTION

[0036] 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.

[0037] In the description of the present invention, it should be understood that descriptions involving orientations, such as up, down, front, back, left, right, etc., and orientations or positional relationships indicated are based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be understood as a limitation on the present invention.

[0038] In the description of the present invention, "several" means one or more, "more" means more than two, "greater than", "less than", "exceed" etc. are understood as not including the number itself, and "above", "below", "within" etc. are understood as including the number itself. If there is a description of "first" or "second", it is only used for the purpose of distinguishing the technical features, and cannot be understood as indicating or implying the relative importance or implicitly indicating the number of the indicated technical features or implicitly indicating the order of the indicated technical features.

[0039] See also Figure 2The structure used for blade winding and forming includes a crimping roller 1, a bending roller 2, a center roller 3, and a stretching rod 4. The unprocessed material is bent and deformed around the center roller 3 under the action of the bending roller 2 and the stretching rod 4 to form a workpiece that meets the shape requirements. Among them, the feeding end on the right side of the figure is the unformed part, and the part after bending is the formed part. The existing quality control method is random inspection after production is completed. This product quality control method is more dependent on the debugging and control capabilities of the operator, and cannot guarantee the fluctuation of corrugation during product processing. At the same time, the random inspection method cannot guarantee the qualified rate of the product, and cannot prevent the flow of unqualified products to the client. In addition, quality problems in the product production process cannot be discovered in time, which is prone to batch quality problems.

[0040] See also Figure 2-5 The present invention is an online monitoring system for the processing quality of piston ring scrapers, comprising: a detection unit 5, a transmission unit and an integrated analysis unit 6, etc. The detection unit 5 is arranged on the scraper winding processing equipment, and is used to detect and obtain the outer circle contour runout data of the formed part of the scraper workpiece being processed in real time and upload and transmit it. The detection unit 5 can be a contact or non-contact sensor. Specifically, the detection unit 5 can be a line laser sensor, a Gocator 3D intelligent line laser contour sensor, a Deep Vision intelligent spectral confocal sensor SC series, a Baumer OX series intelligent 2D contour sensor or a laser displacement sensor. Preferably, the detection point of the detection unit 5 is located at one end of the scraper product forming part close to the unformed part. In this way, the detection data of the forming part can be obtained more timely, and at the same time, problems can be discovered and handled earlier.

[0041] See also Figure 2-5 In one embodiment of the present invention, the integrated analysis unit 6 and the detection unit 5 form a data transmission channel through a transmission unit, and the real-time contour runout data detected by the detection unit 5 is uploaded to the integrated analysis unit 6 via the transmission unit. The integrated analysis unit 6 is used to analyze the received outer circle contour runout data to obtain the real-time waviness and roundness data of the product, and transmit the data to the database 7, display screen, computer (mobile terminal corresponding to the staff) or other external devices after the data analysis is completed.

[0042] See also Figure 2-5 In one embodiment of the present invention, the integrated analysis unit 6 works as follows: after the product starts to be processed, the diameter data of the scraper product being processed (which can be retrieved from the database 7 or manually input at the beginning of the processing) and the processing speed data of the equipment are obtained, and the circumference processing time T of the product is determined according to the diameter of the processed product and the processing speed of the equipment; that is, the time T required for the scraper to wind one circle. Then, the received outer circle contour runout data is analyzed and calculated to obtain the roundness value and the waviness value.

[0043] See also Figure 2-5 In one embodiment of the present invention, the method for obtaining roundness value data is as follows: when the product is processed for less than one circle, starting from the instant detection point, the outer circle contour runout data of the product within the range of the product molding starting end is obtained in the direction of the detected point, the max value and the min value are taken out, and the roundness value is obtained by subtracting them; when the product is processed for a full circle, starting from the instant detection point, the outer circle contour runout data within a range of one circle in the direction of the detected point is taken out, the max value and the min value are taken out, and the roundness value is obtained by subtracting them.

[0044] See also Figure 2-5 In one embodiment of the present invention, the method for obtaining the waviness value data is as follows: starting from the instant detection point, the product outer circle contour runout data within a range of 30° time (T / 12) is obtained in the direction of the detected point, the max value and the min value are taken out, and the waviness value is obtained by subtracting them; when the processing time is less than T / 12 and the processing angle is less than 30°, there is no need to obtain the waviness value, and the roundness value is directly used as the waviness value for calculation.

[0045] See also Figure 2-5 In one embodiment of the present invention, after obtaining the roundness value and the waviness value, they are compared with the preset roundness threshold and the waviness threshold, respectively. If there is no abnormality, the process is processed as usual and the process detection data is recorded for data analysis when necessary in the future. If any of the two parameters exceeds the threshold, an alarm message is issued, and the alarm message may include the alarm reason, such as roundness out of tolerance or waviness out of tolerance. The roundness threshold can be 20μ, and the waviness threshold is 3μ / 30°. That is, the technical requirements of the scraper are roundness ≤20μ and waviness ≤3μ / 30°. The threshold can also be adjusted according to actual conditions. Preferably, the roundness threshold and / or the waviness threshold include a first threshold and a second threshold, and the first threshold is less than the second threshold. When the real-time roundness value exceeds the first threshold, an alarm message is issued, and when the real-time roundness value exceeds the second threshold, an alarm message is issued and the equipment is shut down. Exceeding the first threshold and not exceeding the second threshold indicates that the risk of product failure is increased. At this time, an alarm message can be issued to notify relevant personnel to pay special attention or observe whether there are problems in the processing process and eliminate them. If the second threshold is exceeded, it means that the product is seriously unqualified and has quality problems. It is necessary to shut down the machine in time and notify relevant personnel to deal with it as soon as possible to avoid waste of materials. As an example, the first threshold of roundness can be 15μ, the second threshold can be 25μ, the first threshold of waviness can be 2μ, and the second threshold can be 3μ or 4μ. The second threshold can be set equal to the upper limit of the technical requirements, or it can be slightly higher than the technical requirements to avoid false alarms caused by environmental fluctuations or equipment fluctuations, avoid frequent shutdowns, and avoid measurement errors caused by product jitter.

[0046] See also Figure 2-5 In one embodiment of the present invention, a database 7 for storing outer contour runout data and a display unit 8 for displaying the outer contour runout data obtained by detection and the roundness value data and waviness value data calculated by the integrated analysis unit 6 are also included. The display unit 8 can be used for intuitive data observation. The display unit 8 can be a display screen. The database 7 can be used to store the outer contour runout data information of the relevant products. After the product processing is completed, the roundness value and waviness value change curve can be generated and uploaded for subsequent call. While the product is being processed, the equipment model, raw material batch number, product batch number, and processing personnel data information are obtained and stored in the database 7 together with the roundness value and waviness value change curve. In this way, a mapping relationship between processing quality (roundness, waviness) and equipment model (mold accuracy, assembly accuracy), raw material batch number, product batch number, processing personnel and other data information can be established, so that the influence of mold accuracy, assembly accuracy, and life artificial control on roundness and waviness can be verified, providing guidance for subsequent production work arrangements and indicating the direction for how to ensure processing quality. Recording the batch number can facilitate process traceability when quality problems occur. After processing is completed, the finished products can be re-inspected to verify the correctness of online monitoring and avoid equipment failures that prevent quality problems from being discovered and alarmed in a timely manner.

[0047] The above is a detailed description of an embodiment of the present invention, but the content is only a preferred embodiment of the present invention and cannot be considered to limit the scope of implementation of the present invention. All equivalent changes and improvements made according to the scope of application of the present invention should still fall within the scope of the claims of the present invention.

Claims

1. An online monitoring system for the processing quality of piston ring scrapers, characterized in that: include: A detection unit, which is arranged on the scraper blade winding processing equipment and is used to detect and obtain the outer circle contour runout data of the formed part of the scraper blade workpiece being processed in real time; The integrated analysis unit and the detection unit form a data transmission channel through the transmission unit, and obtain the outer circle contour runout data of the formed part of the scraper workpiece being processed through the transmission channel; and are used to analyze the received outer circle contour runout data to obtain the real-time waviness and roundness data of the product, and its working process is as follows: After the product starts to be processed, the diameter data of the scraper product being processed and the processing speed data of the equipment on which it is located are obtained, and the circumference processing time of the product is determined according to the diameter of the processed product and the processing speed of the equipment; Get roundness value data: When the product is processed for less than one week, the outer contour runout data of the product within the range of the product forming starting end is obtained from the instant detection point to the direction of the detected point, and the max value and min value are taken out and subtracted to obtain the roundness value; When the product is processed for a full circle, the outer circle contour runout data is obtained from the instant detection point in the direction of the detected point within a circle, the maximum value and the minimum value are obtained, and the roundness value is obtained by subtracting them; Get the waviness value data: Starting from the instant detection point, take the product outer circle contour runout data within a range of 30° in the direction of the detected point, take out the maximum value and the minimum value, and subtract them to obtain the waviness value; After obtaining the roundness value and the waviness value, they are compared with the preset roundness threshold and the waviness threshold respectively. If they exceed the threshold, an alarm message is issued.

2. The online monitoring system for the processing quality of piston ring scrapers according to claim 1 is characterized in that: The detection unit is a contact or non-contact sensor.

3. The online monitoring system for the processing quality of piston ring scrapers according to claim 1 is characterized in that: The detection point of the detection unit is located at one end of the formed portion of the scraper product close to the unformed portion.

4. The online monitoring system for the processing quality of piston ring scrapers according to claim 1 is characterized in that: Also included is a database for storing external contour runout data.

5. The online monitoring system for the processing quality of piston ring scrapers according to claim 1 is characterized in that: It also includes a display unit for displaying the outer circle contour runout data obtained by detection and the roundness value data and waviness value data calculated by the integrated analysis unit.

6. The online monitoring system for the processing quality of piston ring scrapers according to claim 1 is characterized in that: The roundness threshold is 20μ, and the waviness threshold is 3μ / 30°.

7. The online monitoring system for the processing quality of piston ring scrapers according to claim 1 is characterized in that: The roundness threshold includes a first threshold and a second threshold, the first threshold is smaller than the second threshold, when the real-time roundness value exceeds the first threshold, an alarm message is issued, and when the real-time roundness value exceeds the second threshold, an alarm message is issued and the equipment is shut down.

8. The online monitoring system for the processing quality of piston ring scrapers according to claim 1 is characterized in that: After the product processing is completed, the roundness value and waviness value change curve are generated.

9. The online monitoring system for the processing quality of piston ring scrapers according to claim 8 is characterized in that: While the product is being processed, the equipment model, raw material batch number, product batch number, processing personnel data information and roundness value and waviness value change curves are obtained and stored in the database.

Images